International Journal of Advanced Manufacturing Technology最新文献

{"title":"An experimental methodology to characterize load-based fracture models of third generation advanced high strength steel resistance spot welds","authors":"Mohammad Shojaee, Cameron Tolton, Abdelbaset Midawi, Tingting Zhang, Hassan Ghassemi-Armaki, Michael Worswick, Cliff Butcher, Elliot Biro","doi":"10.1007/s00170-024-13438-6","DOIUrl":"https://doi.org/10.1007/s00170-024-13438-6","url":null,"abstract":"<p>Failure of resistance spot welds in computer-aided engineering models is based upon criteria that incorporate test data obtained in various loading conditions including different proportions of tensile, shear, and moment loads. The decomposition of the critical load into its respective shear, tensile, and bending moment components is influenced by the rigid body motion during their corresponding mechanical tests. Continuous tracking of the weld orientation and the deformed coupons is required for accurate determination of the load components at the onset of failure. A comprehensive experimental investigation was performed to characterize the critical failure load components in combined loading using various orientations of KS-II tests and a range of coach peel coupon geometries. Mechanical testing was coupled with digital image correlation (DIC) to systematically evaluate empirical force-based failure models for resistance spot welds of two third generation advanced high strength steels with optimal and suboptimal fusion zone diameters. New analysis methodologies using DIC were developed to account for rotation and deformation of the joint in the determination of the shear, normal, and bending moments acting on the spot-welded joints. The coach peel test results for both steels revealed a non-convex experimental fracture locus in bending-tension loading cases. The conventional assumption of a convex failure locus overestimated the critical bending moment strength between 7 and 66%. Results indicated that changes in the operative failure mechanism from pullout/partial-pullout to interfacial can expand the fracture loci within the shear-tensile loading mixities. Improved alternative functional forms for the weld failure models were proposed and contrasted with conventional models that assume convexity.</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":"140172625","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":"Numerical modeling of fill-level and residence time in starve-fed single-screw extrusion: a dimensionality reduction study from a 3D CFD model to a 2D convection-diffusion model","authors":"Erik Holmen Olofsson, Ashley Dan, Michael Roland, Ninna Halberg Jokil, Rohit Ramachandran, Jesper Henri Hattel","doi":"10.1007/s00170-024-13378-1","DOIUrl":"https://doi.org/10.1007/s00170-024-13378-1","url":null,"abstract":"<p>This research delves into the numerical predictions of fill-level and residence time distribution (RTD) in starve-fed single-screw extrusion systems. Starve-feeding, predominantly used in ceramic extrusion, introduces challenges which this study seeks to address. Based on a physical industrial system, a comprehensive 3D computational fluid dynamics (CFD) model was developed using a porous media representation of the complex multi-hole plate die. Validations performed using real sensor data, accounting for partial wear on auger screw flights, show an ~11% discrepancy without accounting for screw wear and ~6% when considering it. A 2D convection-diffusion model was introduced as a dimensionality reduced order model (ROM) with the intention of bridging the gap between comprehensive CFD simulations and real-time applications. Central to this model’s prediction ability was both the velocity field transfer from the CFD model and calibration of the ROM diffusion coefficient such that a precise agreement of residence time distribution (RTD) curves could be obtained. Some discrepancies between the CFD and the ROM were observed, attributed to the loss of physical information of the system when transitioning from a higher fidelity CFD model to a semi-mechanistic ROM and the inherent complexities of the starved flow in the compression zone of the extruder. This research offers a comprehensive methodology and insights into reduced order modeling of starve-fed extrusion systems, presenting opportunities for real-time optimization and enhanced process understanding.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"24 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140172624","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":"Optimization of critical process control parameters in MEX additive manufacturing of high-performance polyethylenimine: energy expenditure, mechanical expectations, and productivity aspects","authors":"Nectarios Vidakis, Markos Petousis, Mariza Spiridaki, Nikolaos Mountakis, Amalia Moutsopoulou, Emmanuel Kymakis","doi":"10.1007/s00170-024-13418-w","DOIUrl":"https://doi.org/10.1007/s00170-024-13418-w","url":null,"abstract":"<p>The demand for 3D-printed high-performance polymers (HPPs) is on the rise across sectors such as the defense, aerospace, and automotive industries. Polyethyleneimine (PEI) exhibits exceptional mechanical performance, thermal stability, and wear resistance. Herein, six generic and device-independent control parameters, that is, the infill percentage, deposition angle, layer height, travel speed, nozzle temperature, and bed temperature, were quantitatively evaluated for their impact on multiple response metrics related to energy consumption and mechanical strength. The balance between energy consumption and mechanical strength was investigated for the first time, contributing to the sustainability of the PEI material in 3D printing. This is critical considering that HPPs require high temperatures to be built using the 3D printing method. PEI filaments were fabricated and utilized in material extrusion 3D printing of 125 specimens for 25 different experimental runs (five replicates per run). The divergent impacts of the control parameters on the response metrics throughout the experimental course have been reported. The real weight of the samples varies from 1.06 to 1.82 g (71%), the real printing time from 214 to 2841 s (~ 1300%), the ultimate tensile strength from 15.17 up to 80.73 MPa (530%), and the consumed energy from 0.094 to 1.44 MJ (1500%). The regression and reduced quadratic equations were validated through confirmation runs (10 additional specimens). These outcomes have excessive engineering and industrial merit in determining the optimum control parameters, ensuring the sustainability of the process, and the desired functionality of the products.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","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":"140172460","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":"In situ repairing of continuous fiber-reinforced thermoplastic composite via multi-axial additive manufacturing","authors":"","doi":"10.1007/s00170-024-13381-6","DOIUrl":"https://doi.org/10.1007/s00170-024-13381-6","url":null,"abstract":"<h3>Abstract</h3> <p>The conventional repairing of CFRP (continuous fiber-reinforced polymer composites) includes complicated steps of patching, splicing, repairing, and post-curing. Intensive labor work needs to be conducted, and poor surface quality and weak interfacial adhesion are usually observed. This work mainly introduces an in situ online repairing method using AM (additive manufacturing) facilitated composite fabrication. With the advances of the robotic-assisted AM process, the surface roughness and accuracy during the repairing process can be evaluated online upon layer-by-layer process. In order to fulfill the efficient and on-site requirements for repairing damage in structural components, this study explores the method including in situ repairing, laser point clouds online collection, and repairing path planning based on multi-axial additive manufacturing of composites. A repair algorithm is proposed incorporating point clouds collection, measurement evaluation, and path planning. Furthermore, relevant mechanical measurements have been conducted, so as to assess the interface degree of recovery. A rapid online evaluation and surface conformal repairing method have been proposed to overcome the technical bottleneck of in situ automatic repairing of damaged composites. It expands the application of multi-axial robot-assisted CFRP AM.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"57 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140156646","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":"The influence of submillimeter morphological variations on the wettability of WEDM-fabricated dual-scale roughness aluminum alloy 6082 surfaces","authors":"Dimitrios Skondras-Giousios, Panagiotis Karmiris-Obratański, Magdalena Jarosz, Beata Leszczyńska-Madej, Angelos P. Markopoulos","doi":"10.1007/s00170-024-13414-0","DOIUrl":"https://doi.org/10.1007/s00170-024-13414-0","url":null,"abstract":"<p>Deriving inspiration from natural hierarchical superhydrophobic surfaces, multi-scale structures were manufactured on AA6082 surfaces via wire electrical discharge machining (WEDM), featuring microscale texture due to spark erosion, superimposed upon a wide-range simple and more complicated geometries of submillimeter profiles. The effect that the higher-order scale morphologies had on wettability was investigated. The dual-scale morphology elevated the hydrophobicity of the surfaces compared to single-scale or unmodified surfaces, reaching superhydrophobicity (151°) in the case of a certain triangular profile. Rectangular and triangular profiles facilitated the higher contact angles, while re-entrant geometries were able to totally prevent cavity wetting. A correlation of static contact angle with roughness parameters of the larger scale such as Ra, Rz, Rp, Rsk, and Rku for certain geometry configurations was identified. Peak hydrophobicity resulted at Ra = 70 μm, Rz = 240 μm, and Rp = 160 μm concerning simple geometries. Negative Rsk and Rku &gt; 1.5 affected negatively contact angle of samples. All investigated tested types were found to reach higher hydrophobicity at moderate drop volumes (5 μl). The fabricated samples were anisotropic in at least two directions, showing decreased hydrophobicity in the front, parallel to the groove direction. When tested in multi-directional dynamic tilting up to 90°, the more complicated geometries were able to retain resistance to spreading. All samples demonstrated superliquiphilicity with lower surface tension liquids, making them strong candidate in applications such as oil/water separation. Finally, all samples tested sustained their hydrophobic character subsequent to a 3-month atmospheric exposure period.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"48 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140150781","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 accuracy reliability optimization of three-axis CNC machine tools using doubly-weighted vector projection response surface method","authors":"Zhiming Wang, Wenbin Lu","doi":"10.1007/s00170-024-13426-w","DOIUrl":"https://doi.org/10.1007/s00170-024-13426-w","url":null,"abstract":"<p>The reasonable allocation of geometric errors of machine tools can improve their machining accuracy reliability (MAR). However, due to the complexity and high nonlinearity of limit state function (LSF) of MAR, the fitting accuracy is usually low when the traditional method is used to approximate LSF. To solve this problem, a doubly-weighted vector projection response surface (DWVPRS) method, which considers not only the approximation results of test sample points (TSPs) to LSF but the distances between TSPs and the most probable failure point (MPFP), is proposed. Using the reliability sensitivity analysis method, the key geometric errors were identified and optimized. Finally, taking a large gantry guideway grinding machine as an example to verifies the effectiveness and correctness of the DWVPRS method proposed in this paper, the results show that compared with the traditional methods, the DWVPRS method has the highest fitting accuracy to approximate LSF at the MPFP, and after the optimization of geometric accuracy, both the minimum and average reliability values of the grinding machine meet the design requirements.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"27 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140150732","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":"Analysis of the causes determining dimensional and geometrical errors in 316L and 17-4PH stainless steel parts fabricated by metal binder jetting","authors":"Marco Zago, Nora Lecis, Marco Mariani, Ilaria Cristofolini","doi":"10.1007/s00170-024-13437-7","DOIUrl":"https://doi.org/10.1007/s00170-024-13437-7","url":null,"abstract":"<p>This work aims at investigating the causes affecting the dimensional and geometrical accuracy of holes in metal binder jetting stainless steel parts. Parallelepiped samples with a through hole were produced using AISI 316L and 17-4PH powders, differing for diameter (3, 4, 5 mm), and position of the axes with respect to the building plane (6, 9, 12 mm distance). Dimensions and geometrical characteristics were measured at green and sintered state by a coordinate measuring machine, determining the dimensional change and the geometrical characteristics. As expected, the shrinkage of linear dimensions is anisotropic; moreover, change in volume and sintered density are significantly affected by the position in the printing chamber. Higher shrinkage was measured along building direction (Z) – 18.5 ÷ 19.5%, than in the building plane – 16.5 ÷ 17.5%, and slightly higher shrinkage – 0.5 ÷ 0.8% was measured along powder spreading direction (X) than binder injection direction (Y). A variation up to 3% in relative density of sintered parts depending on the position in the building plane was observed in 316L. The dimensional change of diameters generally confirmed the shrinkage predicted by the model previously developed—difference between real and expected dimensional changes lower than 3%, except for three geometries (4 ÷ 6%). The cylindricity form error of sintered parts was strongly underestimated by the prediction model (up to 0.15 mm), but underestimation was considerably reduced (generally lower than 0.05 mm) adding the cylindricity form error due to printing. Dimensional and geometrical accuracy of holes are strongly affected by shape distortion of the parallelepiped geometry, in turn due to layer shifting and inhomogeneous green density during printing, and to the effect of frictional forces with trays during sintering. Gravity load effect was also observed on the holes closest to the building plane. Future work will improve the reliability of the prediction model implementing the results of the present work.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"1 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140153929","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 of robotic automation solutions for limp flexible material handling leveraging a finite element modelling technique","authors":"Morteza Alebooyeh, Jill Urbanic","doi":"10.1007/s00170-024-13229-z","DOIUrl":"https://doi.org/10.1007/s00170-024-13229-z","url":null,"abstract":"<p>Fiber composite materials exhibit exceptional specific stiffness and strength compared to traditional engineering materials. Nevertheless, automating the handling of limp flexible materials like fabrics remains a challenging process, often relying on multi-stage manual operations for hand layups. In this study, carbon fabric properties were initially characterized through standard experiments to develop and calibrate a finite element (FE) model. The FE model was subsequently validated against real-world pick-and-place tests involving soft robotic grippers. The validation results demonstrated a high correlation between the FE model and experiments, achieving an average accuracy of 97.2% for fabric projected area and 84.6% for fabric vertices’ displacement. Additionally, the FE model was used to design, evaluate, and optimize alternative automation strategies. It was discovered that a convex surface improved fabric projection area and placement accuracy by 5.9% and 1.9%, respectively, compared to a concave surface with the same curvature radius. Larger concave surfaces contributed to increased projected area and placement accuracy as well. Longitudinal pick-and-place operations also enhanced the projection area and placement accuracy compared to transverse handling processes. Achieving successful fabric pick-and-place operations necessitates a comprehensive system’s approach, considering the interaction between grippers, fabric, and mold surface. The FE model developed in this study will be further employed by the current research team in designing innovative compliant grippers tailored to complex mold surface geometries and specific fabric material requirements. The presented FE model offers valuable insights and paves the way for rapid, efficient, cost-effective, and secure implementation of automation solutions for handling limp flexible materials.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"20 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140156547","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 evaluation of hot stamped boron steel after die punching","authors":"Jincan Wei, Chendong Yang, Shaofei Qu, Yutong Shi, Xianhong Han","doi":"10.1007/s00170-024-13416-y","DOIUrl":"https://doi.org/10.1007/s00170-024-13416-y","url":null,"abstract":"<p>The service performance of hot stamped ultra-high strength steel after die punching was evaluated in this paper through typical experiments, including tensile tests, bending tests, and hydrogen embrittlement tests, as well as characterization analysis. The tested samples were prepared through a specially designed tool by considering different die clearances, punch corner radii, and punch shapes. The results showed that the tensile properties are closely related with the selected punching parameters, while the bending properties and hydrogen embrittlement susceptibility are less sensitive to parameters. Furthermore, the laser cutting method was also involved to produce holes on hot stamped parts and compared with the punching samples. It was found that the laser cutting samples performed better in terms of tensile properties and hydrogen embrittlement susceptibility, which were due to the effects of annealing treatment during laser cutting that decreases the material hardness and brings compressive residual stress near the cutting surface, while the bending properties are insensitive to different drilling methods.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"23 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140153957","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 and application of simulation and optimization for CNC machine tool machining process under data semantic model reconstruction","authors":"","doi":"10.1007/s00170-024-13415-z","DOIUrl":"https://doi.org/10.1007/s00170-024-13415-z","url":null,"abstract":"<h3>Abstract</h3> <p>The digital twin is driving the machine manufacturing and processing workshop to change in the direction of digital intelligence and service. Aiming at the application requirements of virtual simulation monitoring of typical CNC machine tools for the unified interaction and integration of processing and production process data, this paper proposes a development architecture of virtual simulation monitoring and processing process optimization system for CNC machine tools that integrate data, model, communication, and optimization. The data semantic format and data communication are normalized by designing the OPC UA information model of CNC machine tools, modular construction of a three-dimensional digital model, and interactive mapping technology of OPC UA server address space. Virtual simulation visualization and monitoring of CNC machine tools are realized by integrating synchronous simulation modeling, collision detection, and viewpoint control technologies. Building upon this foundation, the control process of the CNC machine tool machining cell is optimized using ECRS and lean production methods. The application focuses on a typical flexible manufacturing cell (FMC) in a machine tool processing and manufacturing workshop. The development of the virtual simulation visualization monitoring system for FMC addresses challenges such as heterogeneous data interaction, sharing, and integration difficulties across multiple heterogeneous equipment. The system successfully fulfills all required functions, and the optimization of the CNC machine tool machining unit’s control process has enhanced equipment utilization and productivity. This solution effectively supports the realization of intelligent manufacturing services, including standardized data-driven digital twins.</p>","PeriodicalId":50345,"journal":{"name":"International Journal of Advanced Manufacturing Technology","volume":"26 1","pages":""},"PeriodicalIF":3.4,"publicationDate":"2024-03-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140150828","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}