Journal of Manufacturing and Materials Processing最新文献

{"title":"High-Precision Integration of Optical Sensors into Metallic Tubes Using Rotary Swaging: Process Phenomena in Joint Formation","authors":"N. Al-Baradoni, Philipp Heck, Peter Groche","doi":"10.3390/jmmp8020060","DOIUrl":"https://doi.org/10.3390/jmmp8020060","url":null,"abstract":"A novel process design for the damage-free and highly accurate positional integration of an optical multi-axial force sensor into a hollow tube by means of rotary swaging is introduced. Numerical simulations reveal the relevant process phenomena of thin disc joining inside a pre-toothed hollow tube and help us to find an optimal process design. Experimental trials show the significant effect of the axial material flow and the number of tools on the rotary swaging process. By taking these effects into account, successful form- and force-fit joining of the sensor carrying discs into the tube can be achieved. Successful joining of an optical sensor for bending force and torque measurement shows hysteresis-free sensory behavior and thus backlash-free joining of the sensor carrier discs. The paper concludes with a presentation of the results of a numerical study on a potential closed-loop approach to the joining process.","PeriodicalId":509245,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"7 S1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140238965","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Minimizing Dimensional Defects in FFF Using a Novel Adaptive Slicing Method Based on Local Shape Complexity","authors":"Ahmed Elayeb, M. Tlija, Ameni Eltaief, B. Louhichi, Farhat Zemzemi","doi":"10.3390/jmmp8020059","DOIUrl":"https://doi.org/10.3390/jmmp8020059","url":null,"abstract":"Additive Manufacturing (AM) has emerged as an innovative technology that gives designers several advantages, such as geometric freedom of design and less waste. However, the quality of the parts produced is affected by different design and manufacturing parameters, such as the part orientation, the nozzle temperature and speed, the support material, and the layer thickness. In this context, the layer thickness is considered an important AM parameter affecting the part quality and accuracy. Thus, in this paper, a new adaptative slicing method based on the cusp vector and the surface deviation is proposed with the aim of minimizing the dimensional defects of FFF printed parts and investigate the impact on the dimensional part tolerancing. An algorithm is developed to automatically extract data from the STL file, select the build orientation, and detect intersection points between the initial slicing and the STL mesh. The innovation of this algorithm is exhibited via adapting the slicing according to the surface curvature based on two factors: the cusp vector and the surface deviation. The suggested slicing technique guarantees dimensional accuracy, especially for complex feature shapes that are challenging to achieve using a uniform slicing approach. Finally, a preview of the slicing is displayed, and the G-code is generated to be used by the FFF machine. The case study consists of the dimensional tolerance inspection of prototypes manufactured using the conventional and adaptive slicing processes. The proposed method’s effectiveness is investigated using RE and CMM processes. The method demonstrates its reliability through the observed potential for accuracy improvements exceeding 0.6% and cost savings of up to 4.3% in specific scenarios. This reliability is substantiated by comparing the resulting dimensional tolerances and manufacturing costs.","PeriodicalId":509245,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"15 6","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140253806","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Characterization of the Dimensional Precision, Physical Bonding, and Tensile Performance of 3D-Printed PLA Parts with Different Printing Temperature","authors":"Rayson Pang, Mun Kou Lai, K. I. Ismail, Tze Chuen Yap","doi":"10.3390/jmmp8020056","DOIUrl":"https://doi.org/10.3390/jmmp8020056","url":null,"abstract":"In this study, tensile test specimens were fabricated using a material extrusion 3D-printer at various printing temperatures to evaluate the development of physical bonds within the same layer as well as in between previous layers. The tensile test specimens were fabricated using PLA material, with printing temperatures ranging from 180 °C to 260 °C. Experimental investigations were conducted to investigate the dimensional accuracy and physical appearance of the parts across printing temperatures. Uniaxial tensile tests were conducted at a strain rate of 1 mm/min and repeated five times for each variable in accordance with the ASTM D638-14 standard. Results showed that increasing the printing temperatures yielded parts with better tensile properties. An approximate difference of 40% in tensile strength was observed between specimens fabricated under the two most extreme conditions (180 °C and 260 °C). The changes in tensile properties were attributed to bonding mechanisms related to interlayer bonding strength and a reduction in voids within the internal geometry. Analysis of the fracture surface using scanning electron microscopy (SEM) revealed fewer and smaller voids within the internal geometry for parts printed at higher temperature. The percentage area of voids reduced significantly when the printing temperature was increased from 180 °C to 220 °C. The tensile properties continuously improved with the printing temperature, with parts printed at 220 °C exhibiting the highest dimensional accuracy. The findings offer insight into the impact of the printing temperature on both the external physical bonds between printed roads, affecting the physical appearance and dimensional accuracy, and the internal bonds, affecting the tensile properties of the fabricated parts.","PeriodicalId":509245,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"4 2","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140263477","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Dissimilar Probeless Friction Stir Spot Welding of Aluminum Alloy and USIBOR®1500-AS Steel Thin Plates","authors":"Mariia Rashkovets, M. Palmieri, N. Contuzzi, L. Tricarico, Giuseppe Casalino","doi":"10.3390/jmmp8020055","DOIUrl":"https://doi.org/10.3390/jmmp8020055","url":null,"abstract":"Lap joining of an aluminum AA6082-T6 plate and a UHSS steel plate coated with an Al-Si layer was performed using Probeless Friction Stir Spot Welding (P-FSSW). The dwell time and rotational speed were controlled in the range of 10–15 s and 1000–1500 rpm, respectively. For all the samples, thermo-mechanical deformation occurred solely within the upper AA6082 plate. A refined grain structure was formed in the aluminum plate close to the surface. The dwell time was responsible for the intensity of the material flow, resulting in stirring between the Al-Si layer and the aluminum plate at 15 s. The microhardness distribution corresponded to the microstructure features.","PeriodicalId":509245,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"6 3‐4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140266024","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The Impact of PP-g-MAH on Mechanical Properties of Injection Molding of Long Glass Fiber/Polypropylene Pellets from Thermoplastic Pultrusion Process","authors":"Ponlapath Tipboonsri, A. Memon","doi":"10.3390/jmmp8020053","DOIUrl":"https://doi.org/10.3390/jmmp8020053","url":null,"abstract":"Long fiber thermoplastic pellets are pellets containing discontinuous reinforced fibers and a matrix, offering excellent mechanical properties, good processability, recyclability, and low cost. Typically, commercial LFTP is manufactured through the hot melt impregnation process, combining extrusion and pultrusion. Although there is a thermoplastic pultrusion process for LFTP production, characterized by a simple machine and an easy method, its mechanical properties have not yet approached those of commercial LFTP. In improving the mechanical characteristics of LFTP manufactured via thermoplastic pultrusion, this research employed polypropylene-graft-maleic anhydride as a coupling agent during the injection molding procedure. The LFTP is composed of polypropylene material reinforced with glass fiber. Mechanical and physical properties of the LFTP were investigated by introducing PP-g-MAH at concentrations of 4, 8, and 12 wt% through injection molding. The results revealed that, at a 4 wt% concentration of PP-g-MAH, the LFTP composites exhibited heightened tensile, flexural and impact strengths. However, these properties began to decrease upon exceeding 4 wt% PP-g-MAH. The enhanced interfacial adhesion among glass fibers, induced by PP-g-MAH, contributed to this improvement. Nonetheless, excessive amounts of PP-g-MAH led to a reduction in molecular weight, subsequently diminishing the impact strength, tensile modulus, and flexural modulus. In LFTP composites, both tensile and flexural strengths exhibited a positive correlation with the PP-g-MAH concentration, attributed to improved interfacial adhesion between glass fibers and polypropylene, coupled with a reduction in fiber pull-out. Based on morphological analysis by SEM, the incorporation of PP-g-MAH improved interfacial bonding and decreased fiber pull-out. The presence of maleic anhydride in the LFTPc was confirmed through the utilization of FTIR spectroscopy. Mechanical properties of LFTP containing 4 wt% PP-g-MAH were found to be equivalent to or superior to those of commercial LFTP, according to the results of a comparative analysis.","PeriodicalId":509245,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"56 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140267508","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Creation of an Aluminum Alloy Template with a Surface Structure by Micro-Milling for Subsequent Replication of the Microstructure to Achieve Hydrophobicity","authors":"Artur Knap, Š. Dvořáčková, Martin Váňa","doi":"10.3390/jmmp8010026","DOIUrl":"https://doi.org/10.3390/jmmp8010026","url":null,"abstract":"This research paper focuses on the fabrication of a microstructure based on a natural structure pattern of hydrophobic properties using micro-milling technology, followed by an investigation of the dimensional accuracy, roughness, and replication of the fabricated microstructure. Design, modeling (CAD system), fabrication, and replication are the steps of this process. Knowledge of biomimetics was used to select the microstructure. The main research aim of the experiments is to verify and extend the applicability of conventional CNC manufacturing technologies to obtain a functional surface structure. The micro-milling was carried out on a conventional DMG MORI CNC machine, a CMX 600 V three-axis horizontal milling center, using an external high-frequency electric spindle clamped to the machine. The machined material was aluminum alloy EN AW 7075. The tool was a 0.1 mm diameter double-edged ball mill made of sintered carbide and coated with TiSiN. The cutting conditions were determined according to the tool manufacturer’s recommendations. To compare the achieved accuracies, the same microstructure was fabricated using PLA technology. For subsequent replication of the sample, the negative of the selected microstructure was created and machined. Subsequently, a positive microstructure was created using the silicone impression material by the replication process. This paper and the experiments performed extend the technical knowledge in the field of manufacturing surface functional structures and confirm the possibility of manufacturing the designed structures using chip and laser machining technology, with achieved discontinuities in the range of 3 to 50 μm. They also highlight the issues of replication of such structures with respect to critical manufacturing locations (geometrical parameters of the structures affecting the functional properties of the structure, venting, replica defects, etc.).","PeriodicalId":509245,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"58 7","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139687107","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Processing and Analysis of Hybrid Fiber-Reinforced Polyamide Composite Structures Made by Fused Granular Fabrication and Automated Tape Laying","authors":"P. Hirsch, Simon Scholz, Benjamin Borowitza, Moritz Vyhnal, R. Schlimper, Matthias Zscheyge, Ondrej Kotera, Michaela Stipkova, Sebastian Scholz","doi":"10.3390/jmmp8010025","DOIUrl":"https://doi.org/10.3390/jmmp8010025","url":null,"abstract":"Fused granular fabrication (FGF) is a large format additive manufacturing (LFAM) technology and focuses on cost-effective granulate-based manufacturing by eliminating the need for semifinished filaments. This allows a faster production time and a broader range of usable materials for tailored composites. In this study, the mechanical and morphological properties of FGF test structures made of polyamid 6 reinforced with 40% of short carbon fibers were investigated. For this purpose, FGF test structures with three different parameter settings were produced. The FGF printed structures show generally significant anisotropic mechanical characteristics, caused by the layer-by-layer building process. To enhance the mechanical properties and reduce the anisotropic behavior of FGF structures, continuous unidirectional fiber-reinforced tapes (UD tapes), employing automated tape laying (ATL), were subsequently applied. Thus, a significant improvement in the flexural stiffness and strength of the manufactured FGF structures was observed by hybridization with 60% glass fiber-reinforced polyamide 6 UD tapes. Since the effectiveness of UD-tape reinforcement depends mainly on the quality of the bond between the UD tape and the FGF structure, the surface quality of the FGF structure, the interface morphology, and the tape-laying process parameters were investigated.","PeriodicalId":509245,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"36 44","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139684224","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental Uncertainty Evaluation in Optical Measurements of Micro-Injection Molded Products","authors":"Vincenzo Bellantone, R. Surace, Irene Fassi","doi":"10.3390/jmmp8010021","DOIUrl":"https://doi.org/10.3390/jmmp8010021","url":null,"abstract":"Optical measurements are increasingly widely used as preferential techniques to evaluate dimensional and surface quantities in micro-products. However, uncertainty estimation is more critical on micro-products than macro, and it needs careful attention for evaluating the obtained quality, the requested tolerance, and the correct setting of experimental process settings. In this study, optical measurements characterized micro-injected products by linear and surface acquisition and considered all the sources contributing to uncertainties. The results show that the measure uncertainty could be underestimated if only the standard deviation on simple measurements is considered; this could cause a significant restriction of the estimated range covering the measured values. Furthermore, the findings confirm that the correct evaluation of the potential uncertainties contributes to accurately assessing the process behavior and improving product quality.","PeriodicalId":509245,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"3 9","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139593168","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Numerical Study of the Cold Metal Transfer (CMT) Welding of Thin Austenitic Steel Plates with an Equivalent Heat Source Approach","authors":"H. Aberbache, Alexandre Mathieu, Nathan Haglon, Rodolphe Bolot, Laurent Bleurvacq, A. Corolleur, Fabrice Laurent","doi":"10.3390/jmmp8010020","DOIUrl":"https://doi.org/10.3390/jmmp8010020","url":null,"abstract":"The CMT (cold metal transfer) arc welding process is a valuable joining method for assembling thin sheets, minimizing heat transfers, and reducing subsequent deformations. The study aims to simulate the CMT welding of thin stainless-steel sheets to predict temperature fields and deformations. Both instrumented tests and numerical simulations were conducted for butt-welding of sheets with a thickness of 1 to 1.2 mm. Weld seam samples were observed to identify equivalent heat sources for each configuration. The electric current and voltage were monitored. Temperature measurements were performed using K-type thermocouples, as well as displacement measurements via the DIC (digital image correlation) technique. Thermomechanical simulations, considering phase changes and the actual seam geometry induced by filler material, were conducted using an equivalent heat source approach. A unique heat exchange coefficient accounting for thermal losses was identified. By incorporating these losses into thermal calculations, a good agreement was found between measured and calculated temperatures. Mechanical calculations allowed for the recovery of the horse saddle form after actual welding, with a relative difference of less than 10% in angular distortion between calculated and measured values.","PeriodicalId":509245,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"34 20","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139595225","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Improving Commercial Motor Bike Rim Disc Hardness Using a Continuous-Wave Infrared Fibre Laser","authors":"J. I. Ahuir-Torres, A. Batako, N. Khidasheli, Nana Bakradze, Guanyu Zhu","doi":"10.3390/jmmp8010018","DOIUrl":"https://doi.org/10.3390/jmmp8010018","url":null,"abstract":"This study is focused on examining the feasibility of applying laser hardening to a commercial metallic bike rim, employing a CW IR fibre laser. The research comprises two main phases. The first phase involves an assessment of the impact of laser parameters on the metallic microstructure, while the second phase involves the actual laser hardening of the bike rim. A comprehensive evaluation encompassing hardness measurements, optical microscopy, and scanning electron microscopy was conducted on the samples. The microstructure type can be manipulated by skilfully adjusting the laser parameters, allowing for the creation of various microstructure variants within the laser-hardened zone for specific laser conditions. In this regard, multiple microstructure types were observed. The hardness of the laser-processed zones exhibited variations corresponding to the specific microstructure. Notably, the molten zone (MZ) and the second heat-affected zone (HAZ II) exhibited the highest levels of hardness. Furthermore, it was observed that a scan overlap of ≥ 75% led to an augmentation in hardness. This study sheds light on the intricate interplay between laser parameters, microstructure, and resultant hardness in the context of laser hardening of metallic materials.","PeriodicalId":509245,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"43 13","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-01-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139599092","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}