Manufacturing Letters最新文献

{"title":"Milling force measurement using a constrained motion dynamometer with compensation","authors":"Jose Nazario,&nbsp;Dylan Pollard,&nbsp;Tony Schmitz","doi":"10.1016/j.mfglet.2025.06.081","DOIUrl":"10.1016/j.mfglet.2025.06.081","url":null,"abstract":"<div><div>This paper describes milling force measurement using a low-cost constrained motion dynamometer (CMD). Comparisons are made to force measurement using a commercial dynamometer. The CMD structural dynamics are used to determine the milling force using in-process dynamic displacement of the CMD. Cutting force measurements are presented for three workpiece materials: aluminum, steel, and titanium alloys. For each workpiece material, the time domain displacement is converted to the frequency domain, a filter is produced by inverting the CMD frequency response function (FRF), and the displacement is used to calculate the cutting force. An algorithm is also presented to compensate for CMD FRF variation with workpiece height. It is demonstrated that the CMD offers an accurate low-cost alternative to a commercially available system.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 694-703"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926692","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":"Development of energy consumption monitoring system for machine tools in accordance with ISO14955","authors":"Jaehak Lee,&nbsp;Dong Yoon Lee","doi":"10.1016/j.mfglet.2025.06.006","DOIUrl":"10.1016/j.mfglet.2025.06.006","url":null,"abstract":"<div><div>This paper presents the development of an energy consumption monitoring program for machine tools, aligning with the international standards of ISO 14955. The program aims to monitor and measure energy usage in real-time, identify energy-intensive components, and ultimately facilitate energy efficiency improvements in the manufacturing industry. The developed system features real-time data integration of energy, pneumatic, ambient temperature and humidity sensor data, along with CNC controller data, allowing for an auto-detection of operating states, providing valuable insights into energy consumption, enabling analysis of energy consumption according to machine behavior. The system was applied to various types of equipment, such as turning centers, milling machines, and automatic lathes. The power consumption ratio for each component was calculated, allowing for the development of targeted energy reduction strategies tailored to each type of equipment. Furthermore, using actual production schedules from a machining company, we calculated the time share in accordance with ISO 14955, enabling accurate monitoring and reporting of energy consumption, and calculating the annual energy consumption based on the time share. Moreover, this study contributes to establishing a benchmark for machine tool energy monitoring in accordance with ISO 14955, thereby encouraging the adoption of similar standards across the industry. A key novelty of this research lies in the comprehensive integration of multiple sensor types (electrical, pneumatic, ambient) with CNC data in real time, strictly adhering to ISO 14955 guidelines by incorporating non-electrical energy sources and automatically detecting operating states. This holistic approach goes beyond common practice in current industrial monitoring systems, providing deeper insights and ensuring standardized energy assessments.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 18-23"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926710","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":"Identifying Tool Wear Stages in Turning Process through Machined Surface Image Analysis Using Convolutional Neural Network","authors":"Sujay B J ,&nbsp;Swarit Anand Singh ,&nbsp;Ankit Agarwal ,&nbsp;K.A. Desai ,&nbsp;Laine Mears","doi":"10.1016/j.mfglet.2025.06.079","DOIUrl":"10.1016/j.mfglet.2025.06.079","url":null,"abstract":"<div><div>Implementing tool wear monitoring approaches is often challenging due to the requirements of directly observing the wear state or integrating sensor-based instrumentation. This work proposes identifying wear stages of a turning tool by analyzing the machined surface quality. An indirect tool wear classification approach is presented to categorize tool wear into three classes - initial wear, steady wear stages, and catastrophic wear during the turning operation. The machined surface images were captured over diverse process parameters to realize labeled datasets for these three wear classes. A pre-trained Convolutional Neural Network (CNN), EfficientNet-b0, was fine-tuned using transfer learning to classify the surface images and predict tool wear stages subsequently. The proposed approach demonstrated the potential to offer an alternative solution to on-machine tool wear monitoring. Although the primary results showed the utility of the proposed approach in predicting tool wear stages, the analysis of misclassifications using confidence scores and heatmaps revealed some discrepancies. It highlighted the need for further research to enhance surface image features that can realize a robust and reliable indirect tool wear classification model.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 678-686"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926826","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":"Effects of mechanical alloying and pulse electric sintering processing parameters on Ti20Al20Cr5Nb5Ni17Cu16Co17 high entropy alloys by response surface methodology","authors":"Ufoma Silas Anamu,&nbsp;Peter Ifeolu Odetola,&nbsp;Peter Apata Olubambi","doi":"10.1016/j.mfglet.2025.06.063","DOIUrl":"10.1016/j.mfglet.2025.06.063","url":null,"abstract":"<div><div>Impact of milling and sintering processes on the relative density (RD) and microhardness (MH) were investigated on TiAl-based (Ti₂₀Al₂₀Cr₅Nb₅Ni₁₇Cu₁₆Co₁₇) high entropy alloys (HEAs) fabricated from pulse electric sintering (PES) process at a constant heating rate (100 °C/min), 5 min dwell-time, and pressure of 50 MPa. A predictive model was created using response surface methodology (RSM) to analyze the impact of sintering temperature and milling time on the process. To minimize the number of experimental trials, uniform-design (UDD) of the RSM was employed in the design of the experiment, hence eliminating the need for a trial-and-error approach often connected with traditional experimental techniques. Observation shows that both milling time and sintering temperature played a crucial role in producing a high level of densification, resulting in improved mechanical characteristics. The optimization model indicates that with 9.7 h milling time and 887.9 °C sintering temperature, it is possible to achieve acceptable outcomes including a 99.72 % RD, porosity percentage of 0.28 %, and MH value of 802.9 HV.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 532-539"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926539","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":"A method to determine electrochemical kinetic parameters for multi-element anomalous co-deposition of Zn-Ni electroplating","authors":"M.F. Yasir ,&nbsp;M. Sundaram ,&nbsp;N. Iyyer ,&nbsp;K. Rajurkar","doi":"10.1016/j.mfglet.2025.06.033","DOIUrl":"10.1016/j.mfglet.2025.06.033","url":null,"abstract":"<div><div>Zinc-Nickel alloy plating, an alternative to the carcinogenic cadmium plating was prepared to study the kinetics of reducing elements Zinc, Nickel, and Hydrogen. A methodology to obtain electrochemical kinetic parameters i.e., exchange current density and cathodic transfer coefficient was demonstrated theoretically and experimentally for anomalous co-depositing multielement plating conditions. The kinetic parameters of Zn-Ni plating are very specific to electroplating solution, as the anomalous co-deposition of Zn and Ni either accelerates or retards each other’s deposition behaviour depending on applied potential, which renders standard values or conventional methods such as data optimization ineffective. A continuum-level FEM simulation based on secondary current distribution was performed to predict the plating thickness at a wide range of applied potentials and were found to be in good agreement with experimental results. The deposition behaviour of Zn and Ni align with the hydrogen suppression model, revealing zinc’s significantly higher exchange current density than nickel. The simulation model can effectively predict current density distribution and plating uniformity to explore electroplating of complex geometry in industrial scale while highlighting distinctions in thermodynamic and practical nobility of Zn and Ni for optimum plating composition.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 269-278"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926671","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":"Dynamic face offset compensation for CNC machine tools","authors":"Jie Gu,&nbsp;John Agapiou","doi":"10.1016/j.mfglet.2025.06.005","DOIUrl":"10.1016/j.mfglet.2025.06.005","url":null,"abstract":"<div><div>Nowadays, the demand of tighter tolerance components requires more accurate machine tools with volumetric compensation. In mass production, post-machining inspection of the workpiece on a Coordinate Measuring Machine (CMM) provides statistical quality control information on the variability of the manufacturing process. The dynamic face offset (DFO) is proposed to compensate the machine tool errors. The method is utilizing the part quality CMM data to determine the specific compensation parameters that are used in the machine tool controller to minimize the machine tool errors for specific part faces. The DFO does not considers the table offset parameters as when using the global offset compensation method. The table errors are incorporated within the local offsets. This paper presents the development of a DFO compensation method utilizing the measurements of the machined part(s). The DFO for 4-axis and 5-axis machine tools is estimated through a model while utilizing the computed deviations between the measured and nominal dimensions of the part. The measuring results before and after compensation are compared and demonstrate that the errors are reduced and compensated successfully.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 9-17"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926694","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":"Exploring surface texturing strategies for improved high-pressure coolant performance in cutting processes","authors":"Tatsuya Sugihara,&nbsp;Toshiyuki Enomoto","doi":"10.1016/j.mfglet.2025.06.082","DOIUrl":"10.1016/j.mfglet.2025.06.082","url":null,"abstract":"<div><div>In recent years, machining operations have been subject to increasingly stringent demands, such as machining difficult-to-cut materials, achieving high-speed and high-precision performance, and reducing environmental impact. Consequently, cutting tools are exposed to extreme thermal and mechanical loads during operations. High-pressure coolant (HPC) technology, which supplies coolant to the cutting zone at pressures of several tens of MPa, has garnered attention as a promising solution to these challenges. However, it has been reported that under certain conditions, HPC can yield minimal or even adverse effects, indicating that its full potential is not consistently realized. This study aims to maximize the effect of HPC by introducing micro groove-shaped surface textures on the cutting tool surface. Our findings reveal that under HPC conditions, the alignment between the coolant supply direction and the groove direction on the tool surface is crucial. When the groove direction is aligned with the coolant supply direction, HPC effectiveness is maximized, significantly reducing tool wear.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 704-708"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926829","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":"An Analysis of Human Preference for Object Orientation in Mechanical Design Visualization","authors":"Yan-Ting Chen ,&nbsp;Cheyn Rodriguez ,&nbsp;Andrew Herbert ,&nbsp;Rui Liu","doi":"10.1016/j.mfglet.2025.06.025","DOIUrl":"10.1016/j.mfglet.2025.06.025","url":null,"abstract":"<div><div>Effective communication of new mechanical designs is critical during the conceptual design stage of product development and has a significant impact on how designers present their work. While 2D technical drawings are widely used to convey the 3D geometry of designs, critical factors of design visualization, such as view selection, including object orientation, rotation, and direction of view, are often overlooked. To enhance communication efficiency and reduce errors, it is essential to establish optimal criteria for presenting mechanical designs. This study explores human preferences for orienting mechanical components, focusing on two common approaches: functionality-based and stability-based orientations. To examine these preferences, two groups of participants with diverse academic backgrounds were tasked with selecting between these two orientations for a set of mechanical designs. Additionally, participants rated their familiarity with each object (on a scale from 0 to 3) to assess how familiarity influences orientation preferences. The findings aim to provide insights into the optimal presentation of mechanical designs, enhancing clarity and effectiveness in design communication. The experimental results reveal that participants with a higher level of familiarity with the design tend to prefer functionality-based orientations, while stability-based orientations are more frequently selected for less familiar designs. Additionally, academic background primarily influences participants’ familiarity with the designs but has minimal impact on their orientation preferences when familiarity is considered. These results provide valuable insights for optimizing the presentation of mechanical designs, enhancing clarity and communication effectiveness in design visualization. By understanding these preference patterns, this study offers practical implications for improving mechanical design communication. Tailoring visualization strategies based on familiarity levels can improve clarity and ensure that design intent is effectively communicated to different audiences. These findings provide a foundation for future research to optimize view selection in mechanical design visualization.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 205-213"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926723","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":"An experimental and numerical study of deformation characteristics in flexible stretch bending using reconfigurable tools","authors":"Chanmi Moon,&nbsp;Sigmund A. Tronvoll,&nbsp;Jun Ma,&nbsp;Torgeir Welo","doi":"10.1016/j.mfglet.2025.06.052","DOIUrl":"10.1016/j.mfglet.2025.06.052","url":null,"abstract":"<div><div>Achieving high dimensional accuracy in metal forming processes is essential as this directly impacts product performance, functionality, and aesthetics. Understanding and controlling the factors that influence deformation behavior in metal forming, including springback and local distortions, can improve product integrity and the efficiency of forming and subsequent assembly operations. This study investigates local and global deformation characteristics of AA6082-T4 extrusions formed in stretch bending, using a novel multi-point reconfigurable die system. The experimental results are supplemented by finite element method (FEM) analysis to assess dimensional characteristics using three different die radii (R1000, R1500, and R1750 mm). The findings highlight the influence of discrete multi-point tool on overall deformation behavior after springback, including chord height de, during kinematically controlled bending and stretching. Furthermore, the results from this study serve to define the range of local deformation ensuring global deformation to remains within acceptable tolerance limits for formed products manufactured with reconfigurable multi-point tools.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 434-441"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926610","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":"Sliding friction behaviour of spark plasma sintered graphite reinforced binderless TiC0.7 N0.3 at elevated temperature","authors":"Gadifele Nicolene Mekgwe ,&nbsp;Ojo Jeremiah Akinribide ,&nbsp;Samuel Olukayode Akinwamide ,&nbsp;Peter Apata Olubambi","doi":"10.1016/j.mfglet.2025.06.056","DOIUrl":"10.1016/j.mfglet.2025.06.056","url":null,"abstract":"<div><div>In this study, high temperature friction behaviour of spark plasma sintered graphite reinforced binderless TiC_0.7N_0.3 based ceramic composite was investigated. Archimedes principle was used to evaluate the relative density of the sintered compact. Subsequently, microstructural characterization was performed prior micro-hardness tests. High temperature friction behaviour of the sintered composites was performed at 5 N and 10 N to determine the wear properties of the ceramic composites. The findings from this study demonstrated that the presence of graphite greatly influenced the properties of binderless TiC_0.7N_0.3 based ceramic composite. Sintered density of 99.6 % was achieved when 1.0 wt% of graphite was used and the frictional behaviour of composite B2 showed reduced coefficient of friction values at both loads. The results obtained on wear tests clearly indicated the lubricating tendency of graphite on TiCN composites.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 473-480"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926613","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}