International Journal of Advanced Manufacturing Technology最新文献

{"title":"Ultrasonic-driven adaptive control of robotic plasma arc cutting for bevel applications.","authors":"Aasim Mohamed, Charalampos Loukas, Momchil Vasilev, Nina Sweeney, Gordon Dobie, Charles Macleod","doi":"10.1007/s00170-025-15331-2","DOIUrl":"https://doi.org/10.1007/s00170-025-15331-2","url":null,"abstract":"<p><p>In heavy industries like oil and gas, and shipbuilding, maintaining process quality is challenging. These sectors face inconsistent manual procedures and a shortage of skilled operators regarding thermal cutting and bevelling for welding preparation tasks. Manual fitting and repetitive quality control modifications, especially during thermal cutting, significantly increase time consumption and hinder productivity. Traditional thermal cutting methods are prone to human error, resulting in inconsistent cut quality, and demand high expertise leading to variability in cut precision, increased rework, and material wastage. The objective of this work is to address these challenges by introducing real-time ultrasonic sensing into a robotic plasma cutting control system to automate the steel plate bevelling process. The ultrasonic sensor enables the system to dynamically adapt to variations in steel plate thickness before cutting, ensuring precise and consistent results. The solution begins by presenting an automated method for measuring thickness and computing bevel distance per sample. Secondly, it proposes adaptive adjustments to cutting parameters per sample, leveraging the ultrasonic sensor data to enhance accuracy and reduce the need for manual intervention. Finally, the approach introduces adaptive robotic path generation for cutting and utilizing real-time ultrasonic sensor data to optimize cutting paths. The outcome of this study is the successful development and validation of an adaptive robotic plasma cutting system for steel plate bevel applications, which leverages real-time ultrasonic sensor data to automate the parameter input process and robotic motion planning, demonstrating improved accuracy and efficiency compared to traditional approaches. The results demonstrate that ultrasonic-driven robotic cutting significantly reduces the average error cut percentage to 4.47% with deviations ranging from 0.13 to 0.23° for the bevel angle and 14.27% with deviations between 0.02 and 0.05 mm for root face deviation, compared to the standard cutting approach which has an average error of 18% with deviations ranging from 0.10 to 0.38 mm and 77.1% with deviation between 0.48 to 0.90°, respectively. This paper highlights the benefits of using advanced sensing technology, particularly ultrasonic sensors, to automate plasma bevel cutting for metal plates in the steel fabrication and welding sectors.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"137 7-8","pages":"3783-3797"},"PeriodicalIF":2.9,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11958415/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143774662","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Shear dominated deformation with curved beaks in folding-shearing.","authors":"Rishabh Arora, Omer Music, Julian M Allwood","doi":"10.1007/s00170-025-15853-9","DOIUrl":"10.1007/s00170-025-15853-9","url":null,"abstract":"<p><p>The deep drawing process in the automotive industry generates up to 45% material waste. To address this issue, the folding-shearing process was developed as a drop-in solution, enabling the formation of parts in pure shear with minimal thickness variation. This process involves folding a blank while collecting the excess material in a region called the 'beak', which is subsequently sheared in-plane using a single set of tools moving in one forming direction. This paper investigates the extent to which the curvature of the geometry of the beak influences the resulting thickness distribution. A combination of physical and numerical trials demonstrates that a beak design with a negative Gaussian curvature reduces the maximum thickening by 65%. This reduction in thickening helps minimise the forming loads and tool wear, thereby improving the overall robustness of the process. An analytical model is proposed to predict the resulting thickness distribution and demonstrates accuracy within a 12.5% deviation from experimental results. Finally, a design map is proposed to instantly identify the optimal beak design parameters without the need for extensive numerical or physical validations while ensuring a minimal thickness change.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"138 11-12","pages":"5959-5978"},"PeriodicalIF":2.9,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12174201/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144334348","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Accurate real-time trajectory generation of circular motion using FIR interpolation: a trochoidal milling case study.","authors":"David Wilkinson, Burak Sencer, Rob Ward","doi":"10.1007/s00170-025-15385-2","DOIUrl":"https://doi.org/10.1007/s00170-025-15385-2","url":null,"abstract":"<p><p>Subtractive manufacturing is undergoing a transformative shift towards sustainability and zero-defect manufacturing. This shift is driving the need for more efficient machining strategies such as dynamic milling. The real-time implementation of dynamic milling toolpaths, composed of circular and cycloidal curve patterns, is challenging due to the kinematic constraints in computer numerically controlled machine tools. Resulting from a rigorous analytical analysis of kinematics, the limitations of current approaches to finite impulse response (FIR) interpolation of circular arc (G02/G03) motion are addressed. A novel hybrid FIR interpolation method is presented which modifies the interpolation style depending on the fundamental geometry of commanded circular motion. The method globally satisfies kinematic constraints and tool centre point position tolerances during circular motion and allows consideration of machine dynamics (i.e., resonant frequencies) within the interpolation strategy. The proposed method outperformed current state-of-the-art methods during benchmarking tests which included a high-performance machine tool and two commercial controllers. Reductions of up to 38% in manufacturing cycle times were demonstrated when interpolating high-speed trochoidal toolpaths with the proposed method.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"137 11-12","pages":"5625-5647"},"PeriodicalIF":2.9,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12006282/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144042400","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Metal transfer and bead formation in plasma arc-based wire arc additive manufacturing with vertical wire feeding.","authors":"Chong Wang, Xin Chen, Wojciech Suder, Jialuo Ding, Goncalo Pardal, Stewart Williams","doi":"10.1007/s00170-025-15793-4","DOIUrl":"10.1007/s00170-025-15793-4","url":null,"abstract":"<p><p>Wire arc additive manufacturing (WAAM) is suitable for building large-scale engineering structures with high deposition rates and relatively low costs. However, in a typical plasma transferred arc (PTA)-based WAAM process using an inclined wire and vertical torch, keyhole defects can occur due to the high arc pressure, and the process is sensitive to the wire-feeding position with respect to the workpiece. Therefore, in this study, a PTA-based WAAM process with a new configuration employing a vertical wire and an inclined plasma torch was investigated for the potential of mitigation of keyhole formation and improvement of process tolerance. In particular, detailed investigations were carried out on the metal transfer mechanisms and bead formation characteristics under various processing conditions. The results show that the new configuration significantly reduces the likelihood of keyhole formation compared with the conventional approach due to the changes in arc pressure and heat distribution. Systematic analysis reveals that process parameters, including wire feed speed, arc current, and plasma gas flow rate, strongly influence droplet transfer stability, melt pool dynamics, and final bead morphology, which offer guidance for future process optimisation.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"138 11-12","pages":"5243-5256"},"PeriodicalIF":2.9,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12174197/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144334347","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"On a simulation-based chatter prediction system by integrating relative entropy and dynamic cutting force","authors":"","doi":"10.1007/s00170-024-13270-y","DOIUrl":"https://doi.org/10.1007/s00170-024-13270-y","url":null,"abstract":"<h3>Abstract</h3> <p>This paper aims to develop a simulation-based chatter prediction system using relative entropy—Kullback-Leibler divergence (KLD), and the NC program can be modified to become non-chatter. Chatter is one of the major concerns when machining mechanical components on a CNC machine. In general, the majority of the previous research methods achieved non-chatter stable machining by assigning the appropriate machining parameters: (1) spindle speed, (2) feed rate, and (3) depth of cut based on the generated SLD (stability lobe diagram). Non-chatter stable machining can also be accomplished by manually adjusting the spindle override percentage on the operation panel or the values in the CNC controller via networking once chatter is detected during the machining processes. The creation of SLD must consider two essential parameters: cutting force coefficients (CFCs) and frequency response function (FRF). The CFCs can be obtained from cutting experiment data related to a paired tool and workpiece, and the FRF can be calculated from the tapping test experiment. Then, the CFCs and FRF are stored in the database of the developed system. The simulation-based chatter prediction calculates the KLD value based on the relativity of the dynamic cutting force and the static cutting forces so as to predict whether there is chatter in the NC program or not. The NC program can be adjusted to become non-chatter if there is chatter predicted. The proposed method has been successfully verified through on-site machining, showing very promising achievement.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"44 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140316970","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Pure niobium manufactured by Laser-Based Powder Bed Fusion: influence of process parameters and supports on as-built surface quality","authors":"","doi":"10.1007/s00170-024-13249-9","DOIUrl":"https://doi.org/10.1007/s00170-024-13249-9","url":null,"abstract":"<h3>Abstract</h3> <p>Niobium (Nb) is a transition metal commonly used as an alloying element for increasing strength, toughness, corrosion resistance, and other properties of steel and superalloys. Pure Nb, however, is a very interesting metal for its excellent superconductivity. This makes it suitable for producing superconducting magnets and devices for particle acceleration systems and particle physics research (e.g., superconducting resonant cavities). In this work, the production of Nb by the Laser-Based Powder Bed Fusion (PBF-LB/M, also known as Laser Powder Bed Fusion or LPBF) process was examined. Manufacturing parameters were investigated to achieve additively manufactured parts with a relative density higher than 99.5% and showing a down-skin surface roughness in the range of 20–70 μm, depending on the inclination angle. Studies related to the limiting angle of self-supported Nb parts were also conducted, and innovative non-contact supporting structures were successfully developed. These allowed to creation of parts with very small overhang angles, without compromising the downward-facing surfaces; indeed at the same time, the as-built surface finish was improved.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"8 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140311984","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A new resistance insert spot welding method for injection-molded FRP–steel component","authors":"Hongli Xu, Xiangfan Fang","doi":"10.1007/s00170-024-13400-6","DOIUrl":"https://doi.org/10.1007/s00170-024-13400-6","url":null,"abstract":"<p>For weight reduction, multi-material designs comprising metal and fiber-reinforced plastic (FRP) components in vehicle body structures have been increasingly used. However, the commonly used resistance spot welding (RSW) technology for car body assembly cannot be employed to join sheet metal and FRPs, limiting the use of FRPs. To solve this problem, a novel resistance insert spot welding (RISW) technique was developed in this work for RSW of steel parts and FRP structure parts made by injection molding. Small inserts were developed by using finite element method and experiments that may be welded to different micro-alloyed and dual-phase sheet steels using the projection welding method. The usual flange width of original equipment manufacturers could be kept unchanged. Using the developed insert and welding parameters, the maximum temperature in the FRPs surrounding the inserts was limited to 255 °C, minimizing the damage to polyamide 6 (PA6) material (with 40 wt% glass fiber). A weldability range between 2.5 and 7 kA could be achieved. The joining strength of RISW between a micro-alloyed HC340 steel in 0.75 mm and 1.5 mm thickness and a 2.5 mm/3.0 mm PA6-GF40 material is 20 to 80% higher than self-piercing riveting (SPR). For high-speed loading, RISW strength increases by 39 to 56% further. Finally, RISW was successfully applied to an FRP–steel roof-frame sub-assembly that consists of 19 simultaneously integrated inserts, achieving 10% weight reduction.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"12 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140303232","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Modeling of the motorized spindle temperature field considering the thermos-mechanical coupling on constant pressure preloaded bearings","authors":"Dongxu Su, Yang Li, Wanhua Zhao, Zhe Nie, Huijie Zhang","doi":"10.1007/s00170-024-13306-3","DOIUrl":"https://doi.org/10.1007/s00170-024-13306-3","url":null,"abstract":"<p>The thermal characteristics of the motorized spindle significantly affect the machining accuracy and efficiency, and many thermal models have been developed to investigate the factors that affect the spindle thermal characteristics. However, the thermomechanical coupling of the bearings with constant pressure preload is rarely considered in the present works. Thus, this paper developed a transient temperature model of motorized spindle to study the influence of the radial thermal stress on the heat generation of the constant pressure preloaded bearings. In this research, an analytical thermal stress model was established first by simplifying the components of the bearings into a rotating ring geometry to calculate the thermal stress loaded on the bearings. Meanwhile, a transient temperature model of the motorized spindle was established based on the finite element method (FEM). Then, the analytical model was integrated into the spindle transient thermal model, so that the heat generated by bearings and the motorized spindle temperature can be revised constantly, through the iterative calculation between these two models. Finally, verification experiments with different work conditions clarify that the proposed transient thermal characteristic model of the motorized spindle is valid, and the study shows that it is necessary to consider the bearing heat generation induced by the radial thermal stress when the spindle runs at a high speed.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"32 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140299164","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Material-structure-process-performance integrated optimization method of steel/aluminum self-piercing riveted joint","authors":"","doi":"10.1007/s00170-024-13483-1","DOIUrl":"https://doi.org/10.1007/s00170-024-13483-1","url":null,"abstract":"<h3>Abstract</h3> <p>To improve the reliability of the connection of various steel/aluminum dissimilar materials, an integrated optimization method of material-structure-process-performance is proposed to realize the optimal design of process parameters. First, the Johnson–Cook material model and failure fracture model are established to ensure the accuracy of the simulation model. Then, an integrated simulation analysis for self-piercing riveted joint forming and tensile mechanical performance is established considering the residual information of the joint forming process. Compared with the experimental results, the accuracy of the established model is higher than the model without considering the residual information. Finally, a hybrid sequence approximate optimization that comprehensively considers the forming quality and tensile mechanical performance is constructed to determine the optimal riveting parameters. Compared with the initial design, the maximum pull-out force, maximum shear force, and maximum peeling force of the optimized design for DC01 and 5754 rivets are increased by 35.66%, 8.6%, and 22.43%, respectively, and the maximum pullout force, maximum shear force and maximum peeling force of the optimized design for HC280 and 5754 rivets are increased by 1.490%, 1.292%, and 6.867%, respectively. Moreover, the accuracy and efficiency of self-piercing riveting process design are improved.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"47 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140299492","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental investigations on mechanical properties of AA6061-T6 aluminum alloy joined by laser welding using digital image correlation","authors":"Jie Sheng, Fanrong Kong, Wei Tong","doi":"10.1007/s00170-024-13488-w","DOIUrl":"https://doi.org/10.1007/s00170-024-13488-w","url":null,"abstract":"<p>In industrial applications of laser welding of aluminum alloys, it is often a challenge to find optimal process parameters to produce welded joints of good quality. This study investigates the effect of changes in welding parameters on the resulting welding defects and tensile properties of laser-welded aluminum alloy joints. A high-power disk laser was used for welding 2.54 mm thick AA6061-T6 sheets with four different sets of process parameters. X-ray computed microtomography and full-field microhardness mapping were first used to characterize the as-welded joints. Surface strain mapping based on digital image correlation and a two-mirror optical setup was applied to tensile testing of welded joints up to ductile failure. It was found that the fusion zone of all four laser-welded joints has similar microhardness levels and spatial distributions. Small pores were detected in all four weld joints, except one had a few large pores. Both microstructural heterogeneities and surface geometric irregularities were found to induce highly non-uniform local tensile deformation in laser-welded joints. One set of laser welding parameters was identified to produce the aluminum welds with the best tensile properties even though its weld joint may contain a few relatively large pores.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"233 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140299499","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}