Yangyang Xu, Liqiang Zhang, Gang Liu, Nana Wang, Jian Mao
{"title":"Tool path optimization with stability constraints for ball-end milling cutters based on frequency domain controlling strategy","authors":"Yangyang Xu, Liqiang Zhang, Gang Liu, Nana Wang, Jian Mao","doi":"10.1007/s00170-024-13069-x","DOIUrl":"https://doi.org/10.1007/s00170-024-13069-x","url":null,"abstract":"<p>Ball-end milling cutters are commonly used for precision processing of complex curved parts in CNC systems. However, the milling process often experiences chatter, leading to final surface damage. To solve the problem, the method of automatically adjusting the tool posture was proposed to avoid chatter problems during the milling process. Frequency response function varies along the processing path. The frequency domain control equation for ball-end milling cutter machining under different operating conditions was established in the feed coordinate system, and the stability of the system at the cutting point can be quickly determined by Nyquist. In order to accurately solve the control equation, a method for solving the Cutter Workpiece Engagement (CWE) boundary under different tool postures was designed. The feasible region for the tool axis was searched based on geometric and stability constraints at each original tool path position. In the feasible domain, the tool axis path was optimized and the tool position file was updated with the constraint of machine tool rotation axis smoothness. Milling experiments were conducted on AL7050-T745 workpiece. From the simulation and experimental results, it can be concluded that milling width and tilt angle have significant impact on the milling process. The method proposed in this article has been experimentally validated in a five-axis ball-end milling experiment.</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":"140172620","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":"Cooling efficiency enhancement using a rapid tool with a surface-cooled waterfall cooling channel","authors":"Chil-Chyuan Kuo, Pin-Han Lin, Jing-Yan Xu, Zhe-Xhi Lin, Zi-Huan Wang, Zhi-Jun Lai, Song-Hua Huang","doi":"10.1007/s00170-024-13429-7","DOIUrl":"https://doi.org/10.1007/s00170-024-13429-7","url":null,"abstract":"<p>The manufacturing technique known as investment casting has found extensive application in producing metal components featuring intricate geometries. The production efficiency of the wax patterns is an essential issue in the investment casting industry, especially for the mass production of wax patterns. A conformal cooling channel (CCC) performs the rapid uniform cooling process for injection molding. However, the significant pressure drop along the cooling channels is a distinct disadvantage of CCC. In this study, an innovative waterfall cooling channel (WCC) was proposed and implemented. The WCC cools the injected products by surface contact, replacing the conventional line contact to cool the injected products. The WCC was optimized using Moldex3D simulation software. Rapid tools with two kinds of cooling channels were designed and implemented. The cooling time of the molded part was investigated using a low-pressure wax injection molding machine. Considering a water cup characterized by a mouth diameter of 70 mm, a height of 60 mm, and a thickness of 2 mm, the experimental results confirmed that the use of WCC can save the cooling time of the product by about 265 s compared with the CCC. This result shows that the WCC can increase cooling efficiency by approximately 17.47% compared with conventional CCC.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"5 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172461","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}
Raihan Quader, Leo Klinstein, David Grewell, Lokesh Karthik Narayanan
{"title":"Evaluation of the influence of ultrasonic vibration on physical, tensile, and morphological properties of fused deposition modeled specimens","authors":"Raihan Quader, Leo Klinstein, David Grewell, Lokesh Karthik Narayanan","doi":"10.1007/s00170-024-13410-4","DOIUrl":"https://doi.org/10.1007/s00170-024-13410-4","url":null,"abstract":"<p>The use of fused deposition modeling (FDM) in printing polymers for various applications has been ever increasing. However, its utilization in printing polymers for high-strength and superior surface finish applications is still a challenge, primarily due to process intrinsic defects, i.e., voids between the layers and the rough exterior arising from unrestrained deposition of molten polymer. This research hypothesizes that application of ultrasonic vibration (USV) post-fabrication could minimize these shortcomings. For this investigation, ASTM D638 Type IV samples were FDM-printed using poly(lactic) acid (PLA). Through screening experiments, an optimized set of ultrasonic parameters was determined. Then, the effect of both-sided ultrasonic application was characterized. Subsequently, the impact of USV on the samples’ physical, tensile, and morphological properties was examined by varying the layer height, infill patterns, and % infill density. Up to 70% roughness reduction was observed as a result of post-FDM ultrasonic application. Additionally, the tensile strength of the samples increased by up to 15.31%. Moreover, for some lower % infill samples, post-ultrasonic tensile strengths were higher than 100% infill control samples. Analysis of scanning electron microscopy (SEM) and X-ray computed tomography (CT) imagery indicated enhanced layer consolidation and reduced void presence in samples treated with ultrasonic. The combination of ultrasonic-generated heat and downward pressure promoted a synergistic squeeze flow and intermolecular diffusion across consecutive layers of polymers. As a result, increased tensile strength and surface finish were achieved while dimensional change was marginal.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"2014 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172508","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}
Haiyang Liu, Xianying Feng, Peigang Li, Yandong Liu, Yanfei Li, Ming Yao
{"title":"Modeling and analysis of thermal behavior of feed system based on full-state thermal contact resistance","authors":"Haiyang Liu, Xianying Feng, Peigang Li, Yandong Liu, Yanfei Li, Ming Yao","doi":"10.1007/s00170-024-13408-y","DOIUrl":"https://doi.org/10.1007/s00170-024-13408-y","url":null,"abstract":"<p>The dual-drive feed system can significantly reduce the effects of nonlinear friction. However, due to the numerous heat sources in its system, the thermal responsive mechanism is still unclear. The reason restricts the realization of high-precision micro-feed. Moreover, the existing thermal simulated model of the machine tool oversimplifies the calculation process of thermal contact resistance (TCR), resulting in a significant error in simulation. Therefore, a full-state TCR calculation model is proposed, and based on the model, a high-precision thermal behavior model of the dual-drive feed system is established. Firstly, the entire deformation process of the asperities is characterized by using fractal theory, and the TCR between the joint parts of the feed system is calculated by considering the thermal resistance of air or grease. A thermal simulated model of the dual-drive feed system is developed based on the solved heat generation and the heat transfer coefficients. Then, the temperature rise characteristics of the dual-drive feed system and the responsive mechanism of thermal deformation under different working conditions are analyzed. The influence of TCR on temperature field distribution and deformation field is discussed. Finally, the experiments on temperature rise and thermal deformation are conducted on the dual-drive feed system. The results of the simulated analysis and experiments show that the accuracy of the simulation can be significantly improved by using the full-state TCR model. The error of the thermal model based on the full-state TCR is much smaller than that of the general TCR model and the without TCR. The accurate description of the TCR has an essential impact on the accuracy of the simulated model, and the obstruction of the heat flow by air or grease cannot be neglected.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"290 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172515","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":"Effects of peening conditions and sheet geometry on spherical to cylindrical deformation shifts","authors":"","doi":"10.1007/s00170-024-13387-0","DOIUrl":"https://doi.org/10.1007/s00170-024-13387-0","url":null,"abstract":"<h3>Abstract</h3> <p>Peen forming is a method for deforming metal sheets by introducing plastic strain near the peened surface through shot impacts. The resulting shape after peen forming is affected by peening conditions (such as shot velocity, shot diameter, and nozzle trajectory) and the specimen size. This study aimed to clarify the mechanism of the spherical to cylindrical deformation shift in peen forming, through experiments and numerical simulations using the finite element method by varying the specimen geometry, nozzle trajectory, and air pressure. The deformation of sheets, 200 mm × 200 mm × 2 mm (length, width, thickness), shifted from spherical to cylindrical at an approximate curvature of 0.4 m<sup>−1</sup>. These shifts occurred at smaller curvatures in wider specimens. Numerical simulation using a three-step finite element method was used to calculate the spherical to cylindrical deformation shift. The simple spherical bending model showed that the deformation shifted from spherical to cylindrical, when the strain in the center of the thickness at the edge of the sheet was compressive. This result was consistent with the experimental and numerical simulation results.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"122 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172623","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":"Real-time surface roughness estimation and automatic regrinding of ground workpieces using a data-driven model and grinding force inputs","authors":"Jing-Yu Lai, Pei-Chun Lin","doi":"10.1007/s00170-024-13434-w","DOIUrl":"https://doi.org/10.1007/s00170-024-13434-w","url":null,"abstract":"<p>This study reports a methodology for predicting surface roughness using data-driven models with grinding force as the input data. Prior to the model training process, the critical grinding parameters for brass material were selected and optimized using the Taguchi method. The experimental grinding force data were then collected and preprocessed into three features: the raw feature as the baseline feature, the statistical feature, and the fast Fourier transform (FFT) feature. The data were imported into a linear regression model as the baseline model and a deep neural network (DNN) model as the proposed strategy. The widely used surface roughness (Ra) of the ground workpiece was experimentally measured and served as the performance index. The model’s performance was evaluated based on the mean absolute percentage error (MAPE) between the predicted and measured Ra values. The validation of the Ra prediction revealed that, among all test combinations, the DNN model with four hidden layers and the FFT feature as the input had the best performance of surface roughness prediction, with a MAPE of 3.17%. The independent testing and evaluation of the DNN model with the FFT feature yielded a MAPE of 6.96%, indicating that the proposed strategy effectively predicted the surface roughness of the workpiece. This work also proposes an automatic regrinding strategy in which the grinding system automatically regrinds the workpiece if the predicted Ra of the workpiece in the previous grinding process exceeds the threshold. Experimental results confirmed that among 24 ground areas, two areas have roughness exceeding the threshold and need to be regrind, and the proposed strategy can correctly identify and regrind these two areas (100% success rate). After automatic regrinding, the workpiece exhibited a roughness lower than the set threshold.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"148 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140173140","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":"Joining of AA5052 to CF/PEEK by friction lap welding","authors":"Jamal Sheikh-Ahmad, Redouane Zitoune, Claire Morel, Jean-François Ferrero, Benoit Vieille","doi":"10.1007/s00170-024-13457-3","DOIUrl":"https://doi.org/10.1007/s00170-024-13457-3","url":null,"abstract":"<p>The joining of aluminum alloy AA5052 and carbon-fiber-reinforced polyether ether ketone (CF/PEEK) by friction lap welding was investigated under different conditions of surface texturing and process temperatures. The joint quality was evaluated by measurement of the tensile shear force and examination of the joint morphology. The aluminum alloy underwent two different types of surface texturing—mechanical engraving and sandblasting. The welding experiments were then conducted under different tool rotational speeds for each. The temperatures across the weld line were measured during the welding process using thermocouples mounted at specific locations. The temperature distribution at the interface was determined by an inverse heat conduction method. It was found that the temperatures at the interface exceeded the melting temperature of PEEK for all testing conditions but was always below PEEK thermal degradation temperature. It was also found that joint performance of mechanically engraved samples increased with the increase of interface temperatures. This was attributed to the increased mechanical interlocking due to the flow of melted PEEK into the engraved sample’s surface features. The joint strength of sandblasted samples did not change considerably with interface temperatures.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"26 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172465","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}
Seyyed Masoud Kargar, Alberto Parmiggiani, Mario Baggetta, Emilio Ottonello, Guangbo Hao, Giovanni Berselli
{"title":"Optimization of a tetrahedron compliant spherical joint via computer-aided engineering tools","authors":"Seyyed Masoud Kargar, Alberto Parmiggiani, Mario Baggetta, Emilio Ottonello, Guangbo Hao, Giovanni Berselli","doi":"10.1007/s00170-024-13314-3","DOIUrl":"https://doi.org/10.1007/s00170-024-13314-3","url":null,"abstract":"<p>This article focuses on enhancing the range of motion (ROM) of the Tetra II joint, a spherical compliant joint consisting of three internally interconnected tetrahedron-shaped elements that achieve motion through elastic deformation. Despite its excellent precision, this specific design is constrained in terms of ROM due to internal contacts among the tetrahedral elements. To overcome this limitation, this study utilizes a computer-aided engineering (CAE) framework to optimize the configuration of the Tetra II joint and enhance its ROM. The resultant optimized joint, referred to as Tetra III, is subsequently compared to Tetra II in terms of both ROM and center shift. Finite element models (FEM) are employed to validate the optimization results and examine how various tetrahedron-shaped geometries impact the joint’s performance. The newly optimized joint exhibits a significantly higher ROM compared to the previous version, while maintaining excellent precision and overall smaller dimensions. Finally, to demonstrate its manufacturability, the Tetra III joint is produced using selective laser sintering (SLS) technology, with Duraform PA serving as the construction material. The successful fabrication serves as a demonstrative example of the improved design of the Tetra III joint.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"40 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172469","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":"Development and optimization of a prediction system model for mechanical properties in rotary friction-welded polyamide joints using the SVM approach and GA optimization","authors":"Elhadj Raouache, Aissa Laouissi, Fares Khalfallah, Yazid Chetbani","doi":"10.1007/s00170-024-13450-w","DOIUrl":"https://doi.org/10.1007/s00170-024-13450-w","url":null,"abstract":"<p>The objective of this experimental study is to utilize rotary friction welding (FW) for assembling similar polyamide materials. The application of the SVM approach enables the development of a predictive model for estimating mechanical properties in RFW processes. Furthermore, the optimization of RFW parameters through GA proves pivotal in selecting optimal welding conditions, providing a variety of choices. The welding parameters considered in this study included rotation speed at five levels and traverse speed at three levels. The strength of the welded samples was characterized by a tensile test. Additionally, temperature measurements were taken to determine the maximum temperature in the joint area. The results demonstrated the dependence of tensile strength and maximum temperature on the rotation speed. Maximum tensile strength is achieved at an optimal rotation speed. Moreover, analysis of variance (ANOVA) indicates that rotation speed is the parameter most influenced by tensile strength.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"122 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172474","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}
Chika Oliver Ujah, Daramy V. V. Kallon, Victor Sunday Aigbodion
{"title":"Corrosion characteristics of high-entropy alloys prepared by spark plasma sintering","authors":"Chika Oliver Ujah, Daramy V. V. Kallon, Victor Sunday Aigbodion","doi":"10.1007/s00170-024-13452-8","DOIUrl":"https://doi.org/10.1007/s00170-024-13452-8","url":null,"abstract":"<p>High-entropy alloys (HEAs) are special type of alloy suitably developed for use in petroleum exploration, energy storage devices, medical implants, etc. This is because they possess excellent corrosion, thermal, and mechanical properties. Corrosion characteristic of HEAs prepared via spark plasma sintering is a top notch as the technique generates corrosion resistant phases and homogenous microstructure. This study was aimed at reviewing recent publications on corrosion characteristics of HEAs processed by SPS in order to develop ways of improving their anti-corrosion properties. The resource materials were obtained from Scopus-indexed journals and Google Scholar websites of peer-reviewed articles published within the last 5 years. From the study, it was revealed that incorporation of some elements (Al, Cr, Ti) into HEAs can improve their corrosion resistance, while addition of some others can reduce their brittleness and enhance their stability and formability. It was recommended that optimization of SPS parameters was one of the strategies of generating better corrosion characteristics in HEAs.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"2014 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172513","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}