International Journal of Advanced Manufacturing Technology最新文献

{"title":"Determination of quality classes for material extrusion additive manufacturing using image processing","authors":"Alexander Oleff, Benjamin Küster, Ludger Overmeyer","doi":"10.1007/s00170-024-13269-5","DOIUrl":"https://doi.org/10.1007/s00170-024-13269-5","url":null,"abstract":"<p>Tools for implementing a systematic quality management are necessary for the use of material extrusion as an additive manufacturing process for products with high quality requirements. Well-defined quality classes are crucial for ensuring that the requirements for a product can be communicated transparently and that the existing properties can be evaluated. Furthermore, there is a lack of capable measurement equipment for the acquisition of process data during the production process. To address these challenges, the present paper introduces an image processing system that determines quality indicators for individual layers in terms of imperfect surface percentages and the number of imperfections. The central element of the hardware is an adaptive darkfield illumination, which leads to high-contrast images. In addition, five types of layer subareas are identified in a segmentation step. Unsupervised machine learning methods are then used to detect imperfections in each layer subarea. In the segmentation, the current layer can be distinguished from irrelevant image background regions with an F-measure of 0.981. For the layer-wise measurement of the quality indicators, relative measurement errors with standard deviations of 25 to 76.1% are found. After evaluating the capabilities of the image processing system, a proposal for limits of quality classes is derived by monitoring several material extrusion processes. For this purpose, three quality classes for each of the five layer subareas are deduced from the process scatter measured by the image processing system. The results are an important contribution to the industrialization of material extrusion in safety–critical areas such as medical technology or the aerospace industry.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"16 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140202998","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":"Spindle unit thermal error modeling and compensation based on digital twin","authors":"","doi":"10.1007/s00170-024-13445-7","DOIUrl":"https://doi.org/10.1007/s00170-024-13445-7","url":null,"abstract":"<h3>Abstract</h3> <p>The thermal error in the spindle unit is substantial and necessitates mitigation. Current models, being predominantly static in nature, have limited efficacy in error control. Integrating digital twin technology for modeling and controlling spindle unit thermal error holds promise in enhancing the machining accuracy of machine tools. Yet, the notion of a digital twin system specifically tailored for spindle unit thermal characteristics remains uncharted territory. To navigate these challenges, this study introduces a novel digital twin system tailored for spindle unit thermal characteristics. This system is poised to revolutionize thermal error modeling and compensation by harnessing the capabilities of digital twin technology. Within this digital twin framework, both the thermal error control model and the analytical thermal characteristic model are seamlessly integrated. The control model is devised as an exponential function, utilizing operational time, inherent time constants, and both initial and equilibrium thermal errors as parameters. Delving deeper, the analytical thermal characteristic model for the spindle system is rooted in a thermal resistance network approach. This leads to a closed-loop thermal characteristic modeling process, culminating in the derivation of a steady-state thermal error. Intricate heat transfer dynamics between spindle components are dissected, and a comprehensive thermal equilibrium equation set is formulated for the spindle unit. This equation set comprehensively accounts for dynamic variations in key parameters such as preload, lubricant viscosity, thermal load intensity, thermal contact resistance, and convective coefficients. To ascertain the time constant, a meticulously designed set of thermal characteristic experiments is executed. Subsequently, the digital twin system embarks on predictive modeling of thermal errors across varied operational conditions. This prediction then forms the foundation for thermal error compensation. With the integration of the present model into the digital twin system, the results are impressive: the absolute average and maximum deviations in thermal elongation, post-error control, stand at approximately 0.40 μm and 1.24 μm, respectively.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"5 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140203181","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":"Multi-scale modeling reveals microstructural and mechanical evolution in GH4169 and DD5 nickel-based superalloys during grinding","authors":"Minghui Chen, Ming Cai, Yadong Gong, Qiang Gong, Tao Zhu, Minglei Zhang","doi":"10.1007/s00170-024-13419-9","DOIUrl":"https://doi.org/10.1007/s00170-024-13419-9","url":null,"abstract":"<p>This study delves into the grinding-induced microstructural and mechanical evolution in high-entropy nickel-based superalloys GH4169 and DD5, underscoring their distinct behaviors under varying machining conditions. Leveraging “Random Substitution” in Material Studio, the research developed intricate atomic models to accurately depict the complex chemical compositions and microstructures of these superalloys. Neper software was employed for multi-scale modeling, specifically analyzing the unit cells of GH4169. A critical focus was placed on the effects of key grinding parameters—depth, spindle speed, and feed rate—on the crystallographic deformation of GH4169, contrasting it with the response of DD5. The study highlighted a notable transition in GH4169’s material removal mechanism from plastic flow to chip spallation at enhanced grinding depths and feed rates, while maintaining lattice integrity at higher grinding speeds. GH4169 consistently demonstrated greater tangential and normal forces during grinding compared to DD5, reflecting intricate machining complexities. The differential crystal orientations between these superalloys significantly impacted the grinding force distribution and heat dissipation during the process. This comprehensive analysis provides pivotal insights into the micro-level grinding process parameters, enriching both theoretical and practical understanding of material machinability in advanced manufacturing contexts. The study’s novelty lies in its application of detailed atomic models and multi-scale modeling to uncover subtle microstructural and mechanical dynamics during the grinding of superalloys.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"6 11 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140203252","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":"Machining behavior and experimental investigation of ultrasonic vibration assisted belt flapwheel flexible polishing","authors":"","doi":"10.1007/s00170-024-13380-7","DOIUrl":"https://doi.org/10.1007/s00170-024-13380-7","url":null,"abstract":"<h3>Abstract</h3> <p>The integral blisk has been widely used in aerospace, and its structural performance is inextricably linked to the blade surface quality. To improve the surface integrity of polished surface, ultrasonic vibration assisted belt flapwheel flexible polishing (UBFP) is proposed. In this study, the polishing principle of UBFP and the effects of vibration on surface generation are investigated, and kinematic analyses and trajectory simulations are performed. Furthermore, the influences of the main processing parameters on the polishing force and surface roughness in UBFP are explored experimentally, and the sensitivity of the main parameters is distinguished by multi-parameter relative sensitivity analysis based on Monte Carlo simulation. The results show that the ultrasonic vibration contributes to the polishing process primarily through kinematic state changing and trajectories interlacing of abrasives. Compared with conventional belt flapwheel flexible polishing, the polishing force decreases by 15.72% and the surface roughness decreases by 17.39%. The compression depth is the most sensitive parameter in the process of UBFP. This study demonstrates the feasibility of UBFP and provides a theoretical and experimental reference for improving the polishing surface quality of the blisk blade.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"2014 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172496","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":"Full cycle numerical simulation during the pulsed laser cladding process considering the interaction between laser and powder","authors":"Han Sun, Chang Li, Xing Han","doi":"10.1007/s00170-024-13455-5","DOIUrl":"https://doi.org/10.1007/s00170-024-13455-5","url":null,"abstract":"<p>During the pulsed laser cladding process, complex thermal accumulation occurs between powder and beam due to the pulsed laser periodic change. The selection of process parameters affects the cladding layer quality, and the correlation between the parameters is high. It is of great significance to obtain high quality cladding layer to determine the influence of the powder-carrying gas nitrogen velocity, powder feeding port diameter, and powder feeding angle on the powder flow, as well as the optimal powder shading rate and the mechanism of powder interaction with pulsed laser beam. In this paper, a gas–solid coupling model during the pulsed laser cladding process of three-beam coaxial powder feeder was established, and the rotating Gaussian heat source function of pulsed laser was written to calculate the temperature, flow velocity, and concentration distribution considering the interaction between laser and powder. The orthogonal test method was used to optimize the process parameters in order to reduce the shading rate of powder and improve the laser energy utilization. On this basis, a full cycle three-dimensional multi-field coupling numerical model for pulsed laser cladding process was established, and the temperature, flow, stress fields, and multi-component heat and mass transfer behaviors were calculated under different powder shading rates. The flow temperature of powder was collected by infrared thermometer and compared with the numerical results, the reliability of the model was verified. This study provides a significant theoretical basis for the full-cycle optimization of process parameters and the improvement of cladding layer quality during pulsed laser cladding.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"122 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172366","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":"Understanding the mechanism of ultrasonic vibration-assisted drilling (UVAD) for micro-hole formation on silicon wafers using numerical and analytical techniques","authors":"Rendi Kurniawan, Shuo Chen, Moran Xu, Hanwei Teng, Jielin Chen, Saood Ali, Pil-Wan Han, Gandjar Kiswanto, Sundaresan Thirumalai Kumaran, Tae Jo Ko","doi":"10.1007/s00170-024-13412-2","DOIUrl":"https://doi.org/10.1007/s00170-024-13412-2","url":null,"abstract":"<p>This study investigated the mechanism of UVAD using numerical and analytical techniques. Silicon wafers possess challenging cutting properties due to their inherent brittleness and susceptibility to cracking along specific crystal orientation. Hence, non-traditional cutting methods like UVAD hold promise for precision micro-hole drilling in silicon wafers. In order to comprehend the mechanism of UVAD, the numerical technique utilized a direct brittle micro-cracking model within a 2D finite element (FE) method. This facilitated a comparative analysis between conventional drilling (CD) and UVAD, with a specific focus on understanding the micro-cracking mechanisms during the mechanical process. This study examined primarily the cutting force, micro-fracture analysis, and cutting energy. The numerical technique effectively predicted micro-cracks within the brittle regime, a task that is challenging to accomplish using analytical methods alone. In parallel, an analytical technique was developed to predict brittle-ductile transition (BDT) lines by analyzing the thrust force and specific cutting energy (SCE), combined with the numerical technique. Various feed rates per revolution were tested to validate the analytical force predictions. The analytical results demonstrate that the force profile corresponds to the transient cutting depth, while the numerical results indicated that the direct brittle micro-cracking model effectively demonstrated the fracture mechanisms, particularly at greater depths of cut. The SCE graph can predict the formation of a ductile regime on the cutting surface of the drilled micro-hole, although predicting micro-fractures on the side edges of the drilled micro-holes remains challenging. Additionally, UVAD demonstrated a reduction in micro-fractures on the sides of drilled micro-holes, particularly at very low feed rates per revolution.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"85 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172499","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":"Performance assessment of mahogany oil-based cutting fluid in turning AISI 304 steel alloy","authors":"Joseph Abutu, Paul Akene, Kabiru Musa, Emmanuel Chukwudi Onunze, Sunday Albert Lawal","doi":"10.1007/s00170-024-13374-5","DOIUrl":"https://doi.org/10.1007/s00170-024-13374-5","url":null,"abstract":"<p>In this study, mahogany seed oil was sourced and prepared, and the performances were compared with mineral oils. The extracted oil was characterized to recognize properties related to pyto-chemical, physio-chemical lubricity and thereafter used along with mineral oil for the formulation of cutting fluid using emulsifying agent, anti-corrosive agent, biocides, and anti-foam agent as additives. These additives were added to oil and water by using 2⁴ full factorial design to achieve the optimal combination. In addition, central composite design (CCD) was adopted for the experimental design, and the performance of the mahogany oil-based cutting fluid (MBCF) was investigated in terms of surface finish, cutting temperature, material removal rate, machine sound level, and chips formation and, thereafter, compared with conventional mineral oil (CBCF) in turning of AISI 304 steel under flood cooling technique. Experimental data were analyzed using analysis of variance (ANOVA) and grey relational analysis (GRA). The experimental findings showed that optimal multi-response performance of the MBCF can be achieved using spindle speed, feed rate and depth of cut of 1100 rev/min, 0.27 mm/rev, and 0.23 mm, respectively, while optimal multi-response performance of CBCF can be achieved with spindle speed, feed rate, and depth of cut of 900 rev/min, 0.62 mm/rev, and 0.23 mm, respectively.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"4 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172814","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":"Feasibility study of using digital twins for conceptual design of air-quenching processes","authors":"Zhuming Bi, Donald Mueller, Aki Mikkola","doi":"10.1007/s00170-024-13444-8","DOIUrl":"https://doi.org/10.1007/s00170-024-13444-8","url":null,"abstract":"<p>The concepts of <i>digital twins</i> (DTs) have been widely studied to predict system performance, shorten design cycles, and implement preventive maintenance, but mainly, in large-scale enterprises. It is extremely beneficial to the whole manufacturing sector, since DTs can be readily implemented in small and medium-sized enterprises (SMEs) with basic <i>computer aided engineering</i> (CAE) tools; over 95% enterprises are SMEs. This paper aims to prove the feasibility of using commercial CAE tools, such as SolidWorks Simulation, to design air-quenching processes for SMEs. SMEs can benefit to explore new business opportunities, reduce system design cycle, and improve existing air-quenching processes. To our knowledge, it will be the first work of adopting DTs in conceptual design of an air-quenching process in sense that (1) the need of simulating an air-quenching process before physical implementation is discussed thoroughly; (2) heat transfer processes are classified, governing mathematical models for various heat transfer behaviors are introduced to present an evaluation model of a heat transfer process; (3) main process variables of air-quenching are identified; (4) a DT of an air-quenching process is developed and simulated to verify the capabilities of commercial SolidWorks Simulation; (5) case studies are developed to show how a CAE tool can be used in DTs. The findings from the reported work are summarized with a debrief of our future work.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"2014 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172470","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":"Research on coated wiper insert for milling of compacted graphite iron","authors":"Jun Tan, Jianping Wang, Xiuqing Hao, Xiaonan Ai, Guoqiang Guo, Lu Lu, Zhenming Yang, Liang Li, Ning He","doi":"10.1007/s00170-024-13453-7","DOIUrl":"https://doi.org/10.1007/s00170-024-13453-7","url":null,"abstract":"<p>Compacted graphite iron (CGI) is increasingly used in industrial production due to its excellent mechanical property, especially in the field of high-performance automotive engine manufacturing, and has become a substitute for gray cast iron (GCI). However, the hard-to-machine problem caused by its excellent physical properties was the main issue affecting the surface quality of the CGI workpiece. As a new type of tool, the wiper insert could effectively improve the surface quality. In order to develop a long lifespan and high-stability wiper insert tool for CGI milling, this study conducted a series of experiments, including tool design and simulation, coating preparation and testing, and tool cutting performance testing. In the optimization of simulation analysis of tool geometric parameters, it was found that the numerical value of curved cutting-edge radius had a more significant impact on the cutting performance of wiper insert. In the coating test, AlCrN-coated wiper insert C with a coating thickness of 2.84 µm had the best load bearing and fracture toughness performance in the coating mechanic test and had the best coating bonding performance in the scratch test. In the milling experiment with a cutting speed of 125.7 mm/min, a feed rate of 0.15 mm/r, and a cutting depth of 0.5 mm, the coated wiper insert C had the longest tool life and the best machined surface quality of the workpiece. Compared to other coated tools, the tool life was extended by at least 15.7%, and the effective cutting area was increased by 20%, which means it was the most suitable tool for machining CGI.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"2014 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172755","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":"Thermal error modeling of electric spindles based on cuckoo algorithm optimized Elman network","authors":"Ye Dai, Xin Wang, Zhaolong Li, Sai He, Baolei Yu, Xingwen Zhou","doi":"10.1007/s00170-024-13327-y","DOIUrl":"https://doi.org/10.1007/s00170-024-13327-y","url":null,"abstract":"<p>In order to improve the accuracy of the thermal error model of the electric spindle, a thermal error modeling method based on the optimized Elman neural network using the cuckoo algorithm is proposed. To analyze the thermal behavior of the electric spindle, an ANSYS analysis approach is utilized to create a temperature map. Based on the simulation analysis outcomes, an experimental platform is established to gather temperature data and thermal displacement data. The electric spindle temperature is optimized through the utilization of fuzzy cluster analysis and the Spearman rank correlation coefficient method in combination. The comparison between the established model and the Elman model and the GA-Elman model proves that the CS-Elman model has good prediction accuracy and stability.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"85 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172462","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}