Manufacturing Letters最新文献

{"title":"Prediction of surface modifications induced by orthogonal cutting of IN718 using uncoated WC-Co and PCBN cutting tools","authors":"F.A.V. da Silva ,&nbsp;H.S. Franzão ,&nbsp;T.F.S. Silveira ,&nbsp;J.C.M. Outeiro","doi":"10.1016/j.mfglet.2025.06.088","DOIUrl":"10.1016/j.mfglet.2025.06.088","url":null,"abstract":"<div><div>This work investigates surface integrity modifications induced by orthogonal cutting of Inconel 718, a nickel-based superalloy widely utilized in aerospace, marine, and automotive industries for its exceptional mechanical strength and thermal stability. Due to the challenges associated with machining Inconel 718, a model was developed to understand the subsurface and surface modifications better. A 2D orthogonal cutting model is developed in Abaqus/Explicit FEA software, integrating a constitutive material model that accounts for strain hardening, strain rate, stress triaxiality, Lode angle, and temperature effects. After simulating the cooling process, the machined workpiece model was exported to Abaqus/Standard. The influence of the key machining parameters, including cutting speed, tool edge radius, and uncut chip thickness on plastic strain distribution and the thickness of the plastically deformed layer beneath the machined surface was determined for two different cutting tool materials, uncoated WC-Co and PCBN. The findings show that higher cutting speeds heightened the thickness of the deformed layer, while increased uncut chip thickness and larger tool edge radii increase subsurface deformation. Finally, the choice between WC-Co and PCBN tools influenced not only the magnitude of plastic deformation but also the thickness of the plastically deformed layer.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 752-758"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926750","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigating die-sinking EDM drilling performance on additively manufactured SS316L steel lattice structures","authors":"Shahid Ali,&nbsp;Albina Aidossova,&nbsp;Nuray Begassilova,&nbsp;Anelya Gissa,&nbsp;Didier Talamona,&nbsp;Asma Perveen","doi":"10.1016/j.mfglet.2025.06.076","DOIUrl":"10.1016/j.mfglet.2025.06.076","url":null,"abstract":"<div><div>Currently, additive manufacturing of lattice structures is extensively investigated in various industrial applications due to its lightweight, high strength-to-weight ratio, and porous architecture. Lattice structures often require additional machining for intended applications such as fastening, implantation, or integration to be effectively utilized. Conventional machining methods, due to direct contact, often lead to substantial deformation, increasing the risk of fractures and cracks, thereby limiting their effectiveness for precision applications. In contrast, Electro-discharge machining (EDM) as a post-processing technique offers effective, crack-less, and precision. This research employed the die-sinking EDM to investigate the hole-drilling in SLM-printed SS316L lattices. L15 Box-Benken design was implemented to investigate the effect of EDM input parameters on output parameters. The input-parameters pulse-on, pulse-off times, and peak current were varied to examine the deterministic EDM characteristics such as material removal rate and overcut of the drilled hole, additionally, the interactions between input and output parameters, and resulting surface morphology were studied. The highest MRR (∼738.2 mg/min) was observed at the highest value of peak current (30 A) and longest pulse on time (160 µs) while it also resulted in the largest overcut (0.337 mm). The results also indicated that among the input parameters peak current makes the largest contribution at 40.42 % to the material removal rate and at 74 % to an increase in overcut</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 651-660"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926810","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Rotary ultrasonic micro-grooving of Silicon: Effects of ultrasonic vibration and feeding speed","authors":"Shah Rumman Ansary ,&nbsp;Sarower Kabir ,&nbsp;Nithin Lalith ,&nbsp;Meng Zhang ,&nbsp;Weilong Cong","doi":"10.1016/j.mfglet.2025.06.084","DOIUrl":"10.1016/j.mfglet.2025.06.084","url":null,"abstract":"<div><div>Silicon is one of the most widely used materials in modern technology and can be considered as the backbone of the semiconductor industry. While micromachining and fabrication of microfeatures on silicon is critically important for various applications, the material’s high hardness and intrinsic brittleness present significant machining challenges. It has been shown by previous studies that rotary ultrasonic surface machining can be effectively employed for brittle materials like silicon. However, micro-grooving using similar processes, which involves distinct material removal mechanisms due to high aspect ratios, has not been studied so far. To address this research gap, in this study, conventional micro-grooving (CµG) and rotary ultrasonic micro-grooving (RUµG) experiments have been conducted on silicon substrates at different feeding speeds to analyze the effects of ultrasonic vibration and processing parameters. The performance of both the processes has been evaluated based on a few key metrics, including cutting forces and edge chipping values. The micro-groove quality and material removal mechanism of those two processes have also been discussed to provide fundamental insights into process dynamics. It has been observed that better quality micro-groove is formed in the RUµG process, characterized by reduced cutting forces, minimal edge chipping, and enhanced groove wall quality.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 718-725"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926831","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Model-based cutting load prediction and feed rate optimization considering cutting conditions and tool wear","authors":"Jun-Young Oh,&nbsp;Wonkyun Lee","doi":"10.1016/j.mfglet.2025.06.070","DOIUrl":"10.1016/j.mfglet.2025.06.070","url":null,"abstract":"<div><div>The feed rate is one of the key factors in determining cutting load during machining processes. Cutting load varies depending on the materials of the tool and workpiece, cutting conditions, and tool wear, all of which significantly impact machining performance and quality. Due to these reasons, both pre-optimization and adaptive control methods have been studied to optimize feed rates. This study focuses on developing and validating a cutting load prediction model and a feed rate optimization model that account for the effects of tool wear in milling processes. The cutting load prediction model is based on orthogonal cutting geometry, allowing for real-time control and accurate prediction of cutting load variations due to tool wear. The feed rate optimization model dynamically adjusts the feed rate to maintain consistent cutting load, regardless of tool condition, improving machining efficiency and stability. Experimental results showed that the cutting load prediction model achieved an average accuracy of over 85%, and the feed rate optimization model successfully maintained consistent cutting load under various machining conditions. These models provide a robust framework for real-time machining optimization, significantly enhancing process stability, productivity, and quality. Moreover, by integrating the effects of tool wear, the models offer comprehensive solutions for industries requiring high precision and extended tool life, such as aerospace and automotive manufacturing.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 594-601"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926546","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimizing formability of incremental sheet forming using the straight groove test assessed with a variable wall angle conical frustum","authors":"Ravi Prakash Singh ,&nbsp;Santosh Kumar ,&nbsp;Edward James Brambley ,&nbsp;Sudarshan Choudhary ,&nbsp;Pankaj Kumar Singh ,&nbsp;Sisir Dhara","doi":"10.1016/j.mfglet.2025.06.054","DOIUrl":"10.1016/j.mfglet.2025.06.054","url":null,"abstract":"<div><div>The current study is focused on Robot Assisted Incremental Sheet Forming (RAISF) of AA 6061 alloys. A simple and streamlined approach is presented to optimize the forming parameters to maximize formability during RAISF; the forming parameters are the tool speed, the step depth, and the tool diameter. The optimized parameters are found using a Design of Experiments (DOE) methodology applied to a straight groove test. Straight groove tests were conducted on 39 samples chosen according to a Central Composite Response Surface Design (CCRSD) methodology. Formability is assessed by considering the groove depth, spring back, and forming time; the combination of tool speed (<span><math><mrow><mn>84.65</mn><mo>,</mo><mi>mm</mi><mo>/</mo><mi>s</mi></mrow></math></span>), tool diameter (<span><math><mrow><mn>12.5</mn><mspace></mspace><mi>mm</mi></mrow></math></span>) and step depth (<span><math><mrow><mn>0.4</mn><mspace></mspace><mi>mm</mi></mrow></math></span>) were found optimal. A Variable Wall Angle Conical Frustum (VWACF) was then fabricated to assess the effect of the optimized parameters on the limiting conical wall angle. Finally, a conical frustum of constant wall angle <span><math><mrow><msup><mrow><mn>60</mn></mrow><mrow><mo>∘</mo></mrow></msup></mrow></math></span> was fabricated, and its forming limit compared with the conventional forming limit of AA 6061 obtained by a Nakajima test.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 453-465"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926612","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Polymer metallization via cold spray: an investigation into the effects of particle hardness and morphology","authors":"Siying Chen ,&nbsp;Fengfeng Zhou ,&nbsp;Bailley N. Reggetz ,&nbsp;Eun Gyung Lee ,&nbsp;M.Abbas Virji ,&nbsp;Aliakbar Afshari ,&nbsp;Martin Byung-Guk Jun ,&nbsp;Semih Akin","doi":"10.1016/j.mfglet.2025.06.039","DOIUrl":"10.1016/j.mfglet.2025.06.039","url":null,"abstract":"<div><div>Metallization on polymers has captured remarkable attention across both industry and academia, facilitating the integration of unique features of polymer and metals. Particularly, direct metallization on polymers is critically important as it eliminates the need for surface activation, substrate heating, and post-processing. In this study, cold spray (CS) particle deposition was employed for direct metallization of a polymer substrate − Acrylonitrile Butadiene Styrene (ABS) − with a focus on characterizing the influence of particle (powder) hardness and their morphologies on resulting deposition. In this regard, both spherical (sp) and irregular (ir)-shaped, copper (Cu) and aluminum (Al) feedstock powders were utilized, acknowledging that Cu is intrinsically harder than Al. The metallization process on the substrate was studied in terms of microstructure, deposition efficiency, film thickness, and adhesion strength. The experimental results showed that the Cu powders achieved higher deposition efficiency (≈2.2-fold for ir-shaped, ≈2.1-fold for sp-shaped), film thickness (≈4.4-fold for ir-shaped, ≈6.4-fold for sp-shaped), and adhesion strength (≈1.9-fold for both ir- and sp-shaped) compared to the corresponding Al powders. Additionally, Cu powders exhibited lower surface porosity (24 % for ir-shaped, 20 % for sp-shaped), in contrast to the Al powders (51 % for ir-shaped, 31 % for sp-shaped). On the other hand, for both types of powders, the ir-shaped powders exhibited higher deposition efficiency (≈1.6-fold for Al and ≈1.7-fold for Cu) than the sp-shaped powders. However, irregular-shaped powders resulted in higher surface porosity (≈51 % for Al-ir, ≈31 % for Al-sp, ≈24 % for Cu-ir, ≈20 % for Cu-sp). Notably, no significant difference in adhesion strength was observed between the spherical and irregular-shaped powders. The findings elucidate the intricacies of the CS technique, contributing to functional metallization on polymeric substrates.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 325-331"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926619","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Spark plasma sintering – Assisted embedding sapphire fiber optic sensor into stainless steel 316L: Thermo-electric-mechanical finite element analysis","authors":"Kishore Mysore Nagaraja ,&nbsp;Xinchang Zhang ,&nbsp;Gabriel Martin Garcia ,&nbsp;Wei Li","doi":"10.1016/j.mfglet.2025.06.042","DOIUrl":"10.1016/j.mfglet.2025.06.042","url":null,"abstract":"<div><div>This research incorporates a finite element modeling (FEM) approach to investigate thermo-electric-mechanical coupled behavior in the spark plasma sintering (SPS) process to embed sapphire fiber optic sensor into stainless steel 316L. This SPS-assisted sensor embedding process reported from the literature demonstrates the successful integration of the sapphire fibers within stainless steel 316L powders, achieving high density and strong fiber-powder bonding. The process parameters involve temperature gradient, pressure, and electrical charge input, which significantly influence this bonding. In this study, the FEM simulations were used to model the temperature and stress distribution during the SPS process to investigate temperature heterogeneity and stress gradients within the sintered material embedded with fiber. The results highlight the role of electric current density in influencing the thermal and mechanical behavior of the material. These findings provide insights for optimizing the SPS process conditions to improve the material properties to effectively integrate the optical fibers into sintered powder material for high-temperature applications.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 350-357"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926622","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Manufacturing shear-thickening-gel applied carbon fibre-reinforced polymer (SACFRP) with high toughness and enhanced impact-resistant performance","authors":"Wanrui Zhang ,&nbsp;Jianchao Zou ,&nbsp;Zijing Hong ,&nbsp;Lei Yang ,&nbsp;Weizhao Zhang","doi":"10.1016/j.mfglet.2025.06.043","DOIUrl":"10.1016/j.mfglet.2025.06.043","url":null,"abstract":"<div><div>The brittle nature of carbon fibre-reinforced polymer (CFRP) causes it to be vulnerable to out-of-plane low-velocity impact (LVI). This work developed a novel manufacturing method for shear-thickening-gel applied carbon fibre-reinforced polymer (SACFRP) to mitigate brittleness and improve impact performance. The unidirectional (UD) carbon fibre fabrics were treated with the solution of dissolved shear thickening gel (STG) in xylene. Following the evaporation of the solvent, STG applied carbon fabrics (SACFs)<!--> <!-->were placed according to the specified stacking sequence and impregnated<!--> <!-->with epoxy resin to manufacture<!--> <!-->the SACFRP laminates using the hot-press moulding technique. Different from existing works of STG-based flexible composites, this study firstly fabricated STG-based rigid fibre-reinforced composite laminates for load-bearing and impact-resistant applications. Results of SEM analysis revealed a strong bonding performance between carbon fibres and STG in SACF and SACFRP composites. Static tensile tests of transversely orientated UD SACFRP demonstrated an approximate 147 % increase in specific toughness relative to the reference CFRP equivalent. The reduced deflection and significantly decreased integrity loss of SACFRP laminates under 35 J LVI indicated their superior impact-resistant performance compared to its reference CFRP counterpart. The impact process analysis demonstrated the difference in the resistance mechanisms between SACFRP and its reference CFRP laminates under LVI. SACFRP laminates resist impact loads primarily via the flexural deformation, whereas the impact energy is principally absorbed by the damage to the reference CFRP laminates. Therefore, the novel SACFRP developed in this study, due to its enhanced toughness and impact performance, possesses considerable potential for structural applications under extreme impact<!--> <!-->loading conditions.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 358-363"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926623","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Integrated Product-Platform design and Multi-Period Lot-Sizing for hybrid manufacturing with fuzzy demand and variant substitution","authors":"Abdullah Al Rahi ,&nbsp;Hany Osman ,&nbsp;Ahmed Azab ,&nbsp;Fazle Baki","doi":"10.1016/j.mfglet.2025.06.030","DOIUrl":"10.1016/j.mfglet.2025.06.030","url":null,"abstract":"<div><div>This study develops an integrated mathematical formulation for hybrid manufacturing, incorporating product platforms, multi-period lot-sizing, and fuzzy demand to address demand uncertainty and product variation challenges. Applying the fuzzy set theory, demand is modeled as fuzzy demand, providing a more effective approach to handling uncertainty than deterministic methods. The model includes a substitution strategy to accommodate dynamic changes in variant requirements, enhancing production flexibility. Additionally, based on the developed fuzzy optimization model, the fuzzy model is employed to train a regression model that predicts costs as a function of anticipated confidence levels. The proposed model is validated through a case study, demonstrating its effectiveness in minimizing total production costs and efficiently managing multiple product variants across different planning periods. The findings offer adaptive production planning strategies for manufacturers facing fluctuating demand and high product variety.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 243-252"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926668","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"3D bioprinting of multicellular constructs using HepG2 and HUVEC cells for in-vitro liver models","authors":"Neshat Hojjati ,&nbsp;Kumar Singarapu ,&nbsp;Akash Deep ,&nbsp;Sundararajan V. Madihally ,&nbsp;Srikanthan Ramesh","doi":"10.1016/j.mfglet.2025.06.097","DOIUrl":"10.1016/j.mfglet.2025.06.097","url":null,"abstract":"<div><div>Drug-induced liver injury is a major concern in drug development, often leading to drug failures, withdrawals, and cases of acute liver failure. Accurately predicting the liver’s response to the cytotoxic effects of drugs remains a challenge. While animal models have traditionally been used to study liver toxicity, they often fail to fully replicate human liver physiology. In-vitro models are being actively explored as more relevant alternatives. Among these, 3D bioprinting offers the potential for creating liver constructs that better mimic the complex architecture and cellular composition of the liver. However, a significant challenge with 3D bioprinting is the crosslinking of bioinks, which typically involves chemicals, high temperatures, or UV light conditions that can compromise cell viability and function. To address this issue, this study developed a chitosan–gelatin bioink that forms a gel at body temperature, eliminating the need for harsh crosslinking steps. We optimized bioprinting parameters, including deposition rate, substrate properties, and cell density, to improve cell viability and function. Results showed that slower deposition rates (30 µL/min) and soft chitosan substrates enhanced cell viability compared to rigid substrates. Multicellular bioprinting of HepG2 hepatocytes and human umbilical vein endothelial cells (HUVECs) maintained over 70 % viability by day 5, similar to controls. A 2:1 HUVEC-to-HepG2 ratio further increased urea production to physiological levels (200 mg per 10⁶ cells per day), with stability maintained through day 7. We also demonstrate that these chitosan–gelatin bioinks can be used to print co-culture models that physiologically mimic liver architecture. These models hold potential for future applications in studying drug-induced liver injury.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 825-831"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926689","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}