CIRP Journal of Manufacturing Science and Technology最新文献

{"title":"Two-stage LP/NLP feedrate optimization for spline toolpaths","authors":"Katharine Nancy DiCola ,&nbsp;Christina Qing-Ge Chen ,&nbsp;Serafettin Engin (3) ,&nbsp;Kaan Erkorkmaz (1)","doi":"10.1016/j.cirpj.2025.04.005","DOIUrl":"10.1016/j.cirpj.2025.04.005","url":null,"abstract":"<div><div>Feedrate optimization is an inherently nonlinear and complex problem, but also critical to enhancing the productivity of multi-axis machining operations. This paper presents a new approach to utilize linear programming (LP) alongside nonlinear programming (NLP) in a dual windowing configuration, for optimizing the feed profile for long spline toolpaths. LP is able to handle kinematic constraints of limiting axis velocity, acceleration, and jerk. NLP, afterwards, solves the minimum time problem subject to less conservative, albeit nonlinear, motor torque and servo error constraints. While NLP adds nearly an order of magnitude computation time, in the simulation case studies conducted, it was seen to improve motion time by typically 30 %. The optimized trajectory was also tested on a 3-axis router.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 122-137"},"PeriodicalIF":4.6,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143891778","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Tribo-electrical performance of TiB2/Cu laser cladding-remelting layer under high-current sliding contact","authors":"Yuankai Zhou,&nbsp;Yuxin Jiang,&nbsp;Xue Zuo,&nbsp;Da Wen","doi":"10.1016/j.cirpj.2025.04.011","DOIUrl":"10.1016/j.cirpj.2025.04.011","url":null,"abstract":"<div><div>Slip rings are prone to wear under high-current conditions, resulting in wind turbine failures. To enhance durability, TiB₂/Cu coatings were fabricated on the surface of slip rings using laser cladding and remelting technologies. The tribo-electrical performance of coatings under high-current sliding contact was investigated and the effect of laser cladding-remelting on the tribological and electrical properties of coatings was revealed. The results demonstrate that, compared to the cladding layer, the dilution rate, conductivity, and hardness of remelting layer were increased by 11 %, 2 %, 12 % respectively, and the porosity, longitudinal and transverse residual stress were reduced by 70 %, 33 %, 61 % respectively. At a current of 50 A, the service life of remelting layer was extended, and wear loss was significantly reduced while maintaining a high current-carrying efficiency of 95.2 %. Additionally, due to a new hard phase TiC generated in laser process, as well as the increased melting point of coating, the hardness, wear resistance and softening resistance of the TiB₂/Cu layer were improved.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 111-121"},"PeriodicalIF":4.6,"publicationDate":"2025-04-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143891777","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Electrochemical milling–grinding of high volume fraction SiCp/Al composites with high surface quality via trajectory and process optimization","authors":"Guodong Miao,&nbsp;Xiaolong Fang,&nbsp;Zhao Han,&nbsp;Ningsong Qu","doi":"10.1016/j.cirpj.2025.04.010","DOIUrl":"10.1016/j.cirpj.2025.04.010","url":null,"abstract":"<div><div>Silicon carbide particle-reinforced aluminum matrix (SiC_p/Al) is a composite material that is difficult to machine, particularly at high volume fractions. This study investigated the feasibility and stability of machining high volume fraction SiC_p/Al using electrochemical milling–grinding (ECMG). Unstable electrochemical discharge machining (ECDM) can easily occur during traditional vertical plunge ECMG. Burn marks were observed on the machined surface, and energy-dispersive X-ray spectroscopy detected the presence of tool electroplating materials such as Ni and Cu on the workpiece, implying tool material adhesion. Modeling and simulations of the electrolyte flow field during the ECMG process demonstrated the critical role of electrolyte convection in material removal. A slow electrolyte flow velocity allowed machining debris and heat to build up in the machining gap, creating favorable conditions for abnormal discharge and material removal via ECDM. Therefore, the tool trajectory was modified from the original vertical plunge cut followed by horizontal cutting to an angled cut followed by reversed horizontal cutting. Simulation results indicated that the modified tool trajectory improved electrolyte flow field uniformity and velocity in the machining gap. Consequently, the electrolyte in the machining gap was continuously refreshed, leading to a stable ECMG process that was confirmed by the electrical signals collected from the power supply during machining. Finally, the voltage, cutting depth, and feed rate parameters were optimized to increase the grinding effect and machining efficiency, thereby improving the surface quality of the machined material. A 90 mm × 25 mm plane SiC_p/Al specimen with a volume fraction of 63 % was successfully processed using the modified trajectory with the optimal parameters.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 98-110"},"PeriodicalIF":4.6,"publicationDate":"2025-04-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143882084","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation on the cryogenic cutting performance of birch","authors":"Liyun Qian ,&nbsp;Feng Zhang ,&nbsp;Zhenhua Qing ,&nbsp;Zhanpeng Hao ,&nbsp;Xiaolei Guo","doi":"10.1016/j.cirpj.2025.03.012","DOIUrl":"10.1016/j.cirpj.2025.03.012","url":null,"abstract":"<div><div>In wood cutting, reducing the temperature during cutting can improve machining accuracy and quality. However, traditional coolants are not suitable for reducing the cutting temperature of wood because they will contaminate the machined surface of the wood and affect the health of the operator. Supercritical carbon dioxide (ScCO<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span>) cooling technology is one of the ways to solve such problems, as ScCO<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span> is a sustainable energy technology that can bring high efficiency, environmental protection, and cost-effectiveness. Dry turning and ScCO<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span> turning tests were carried out on birch, respectively, to compare the results of cutting temperature, cutting force and surface roughness characteristics during the process, and to study the cutting performance of ScCO<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span> turning of birch. The results show that the cutting depth has the greatest influence on the cutting temperature and cutting force during dry cutting and cryogenic cutting. ScCO<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span> turning compared with dry turning, the temperature of the cutting area decreases, the cutting force increases. As the cutting temperature is reduced, the brittleness of the wood fibers improves, and the degree of elastic–plastic deformation produced by the action of the cutting tool is smaller, resulting in a decrease in surface roughness and obtaining better machined surface quality. Moreover, under dry cutting conditions, the surface roughness <span><math><msub><mrow><mi>R</mi></mrow><mrow><mi>a</mi></mrow></msub></math></span> decreases and then increases with the increase of cutting speed; under ScCO<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span> cutting conditions, both the cutting force and surface roughness <span><math><msub><mrow><mi>R</mi></mrow><mrow><mi>a</mi></mrow></msub></math></span> decrease with the increase of cutting speed. Therefore, under the premise of obtaining the same cutting quality, cryogenic cutting can use higher machining speed, which helps to improve machining efficiency. This study analyzes the machining performance of turning birch under ScCO<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span> conditions to provide theoretical and application references for the application of ScCO<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span> in the field of wood cutting processing.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 88-97"},"PeriodicalIF":4.6,"publicationDate":"2025-04-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143873469","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Adaptive reference-points learning and cooperation driven multi-objective algorithm for hybrid group flow shop with outsourcing option","authors":"Xinrui Wang ,&nbsp;Junqing Li ,&nbsp;Jiake Li ,&nbsp;Ying Xu","doi":"10.1016/j.cirpj.2025.04.006","DOIUrl":"10.1016/j.cirpj.2025.04.006","url":null,"abstract":"<div><div>With the development of economic globalization, group scheduling with outsourcing option has attracted much attention. This study considers a hybrid flow shop with group and outsourcing constraints, named HFGSP_OO. To solve this problem, adaptive reference-points learning and cooperation driven multi-objective algorithm (ARPCMOA) is proposed to optimize makespan, total energy consumption (TEC) and outsourcing cost, simultaneously. First, according to the characteristics of the problem, a strategy for determining the group to be outsourced is considered to generate the promising initial solutions. Second, a two-stage co-evolutionary method is used to explore the solution space in depth. In the first stage, a hybrid local search (HLS) is proposed to obtain more extreme solutions. In the second stage, the reference points adaptation mechanism is employed to enhance the global search capability of the algorithm, which can select high-quality solutions. These two stages are working cooperatively during the iterative process so that the population evolves towards the true Pareto front. In addition, an energy saving strategy based on idle time is proposed to better optimize TEC. Finally, a large number of statistical analysis experiments (KW) show that ARPCMOA outperforms existing multi-objective algorithms.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 56-75"},"PeriodicalIF":4.6,"publicationDate":"2025-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143863891","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Amorphization of pure aluminium in ultraprecision cutting process: experimental observation and theoretical analysis","authors":"Chunlei He ,&nbsp;Shuqi Wang ,&nbsp;Jiwang Yan","doi":"10.1016/j.cirpj.2025.04.007","DOIUrl":"10.1016/j.cirpj.2025.04.007","url":null,"abstract":"<div><div>Preparing amorphous pure metals has long been significantly challenging because of their stringent transformation requirements. Here, we report a surprising discovery: the preparation of a layer of amorphous aluminium by ultraprecision cutting a polycrystalline bulk material. The findings indicated that under specific cutting conditions, polycrystalline aluminium was transformed into a completely amorphous phase on the surface layer. Additionally, the material matrix exhibited shear bands, including an amorphous phase, a 9 R phase, and high-density SFs. The modification resulted in a significant increase in surface micro-hardness, with the average value increasing from 0.93 ± 0.13 GPa to 2.21 ± 0.92 GPa. The amorphization in the ultraprecision cutting process is attributed to the high shear strain and strain rate, as confirmed by molecular dynamics simulation and theoretical calculation. This study provides a novel approach for preparing an amorphous layer on a crystalline aluminium bulk material to enhance its surface properties.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 76-87"},"PeriodicalIF":4.6,"publicationDate":"2025-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143864022","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Novel net-shape manufacturing of bioresorbable coronary stents using micro-injection molding process","authors":"Dharmendra K. Tyagi,&nbsp;Dhiraj K. Mahajan","doi":"10.1016/j.cirpj.2025.04.002","DOIUrl":"10.1016/j.cirpj.2025.04.002","url":null,"abstract":"<div><div>The bioresorbable cardiovascular stent (BCS) represents a significant advancement in medical technology, offering temporary support to diseased arteries while eliminating the long-term risks associated with permanent implants. However, traditional fabrication methods involve multiple steps, rendering BCS a costly medical device. To address this challenge, net-shape manufacturing techniques have emerged as a promising approach to streamline production and facilitate mass manufacturing. Micro-injection molding (μIM) is a viable method for producing BCS with precise geometries and surface finishes. Yet, the inherent complexities of BCS geometry and the poor melt flow index (MFI) of material present significant obstacles to successful μIM fabrication. In this study, poly-lactic acid (PLA), was modified with triethyl citrate (TEC), a bio-based plasticizer, to enhance its MFI and processability. A comprehensive characterization of the PLA-TEC formulations was conducted, encompassing mechanical strength, thermal stability, and rheological behavior, to optimize material performance for μIM. Subsequently, process parameters were optimised utilising response surface methodology to mitigate manufacturing defects such as underfilling and flash formation, ensuring the production of high-quality BCS. Through systematic material modification and process optimization, this study successfully demonstrates the feasibility of μIM for cost-effective, high-volume production of BCS with improved geometric fidelity.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 25-37"},"PeriodicalIF":4.6,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143839770","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Determination of sawing temperature in multi-diamond wire sawing of mono-crystalline silicon carbide","authors":"Eyob Messele Sefene ,&nbsp;Chao-Chang A. Chen ,&nbsp;Steve Hsueh-Ming Wang","doi":"10.1016/j.cirpj.2025.04.004","DOIUrl":"10.1016/j.cirpj.2025.04.004","url":null,"abstract":"<div><div>4H-silicon carbide (4H-SiC) is a superior polytype SiC known for its wide bandgap, excellent thermal stability, and outstanding electrical and mechanical properties. However, slicing thinner 4H-SiC wafers using diamond wire sawing (DWS) process generates significant heat due to the extended contact length between the diamond wire and work material. This heat adversely affects the surface quality of as-sawn wafers, accelerates diamond wire wear, and poses challenges in accurately measuring the sawing temperature due to the heat dissipation through the unsliced ingot thickness. To address this, the study employed a rocking mode sawing strategy to mitigate the temperature rise caused by the prolonged contact length, while Fourier’s thermal conduction law and finite element analysis (FEA) were employed to accurately evaluate the sawing temperature. The study compares the measured sawing temperatures under rocking mode and traditional sawing conditions with Fourier’s and FEA simulations. Additionally, the effect of sawing temperature on the surface quality of the as-sawn wafer and diamond wire wear has been examined. Results demonstrate that the rocking mode sawing strategy effectively minimizes sawing temperature by 8.266 % in contrast to the traditional sawing process, attributed to its reduced contact length. Fourier’s thermal conduction law analysis proved instrumental in accurately determining sawing temperature. Notably, the rocking mode sawing strategy substantially enhanced the surface quality and reduced the diamond wire wear rate in contrast to the traditional sawing process.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 38-55"},"PeriodicalIF":4.6,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143845202","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Dynamics and stability of high axial depth milling of thin-walled parts","authors":"Saltuk Yildiz ,&nbsp;Lutfi Taner Tunc ,&nbsp;Erhan Budak","doi":"10.1016/j.cirpj.2025.04.001","DOIUrl":"10.1016/j.cirpj.2025.04.001","url":null,"abstract":"<div><div>In finish milling of thin-wall parts, chatter stability is governed by the dynamic response of both the milling tool and workpiece. In the literature, most of the stability models consider single-point contact with shallow axial cutting depths, i.e., point milling, where the mode shape dependent dynamic response is ignorable. On the other hand, as far as high depth milling processes, i.e., flank milling, are concerned there is a line of contact along the axial direction of the milling tool, rather than a single-point of contact. Consequently, mode shape dependent dynamic response turns out to be significant for accurate prediction of stability limits. In this study, the axial variation in the frequency response function (FRF) of the milling system is considered in prediction of stability diagrams. The novel contribution of this study is the experimental verification of the proposed stability model by using a practical workpiece dynamics model. In this respect, the validity of the proposed model was examined under various cases to provide an understanding to develop chatter-free machining strategies, and to demonstrate significant advantage of considering the mode shape dependent FRF variation along the axial direction.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 15-24"},"PeriodicalIF":4.6,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143839769","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Evaluating the impact of boundary conditions and clamping force in robotic one-up drilling of hybrid stacks","authors":"Martina Panico ,&nbsp;Eva Begemann ,&nbsp;Andreas Gebhardt ,&nbsp;Felix Hartmann ,&nbsp;Tobias Herrmann ,&nbsp;Antonio Langella ,&nbsp;Luca Boccarusso","doi":"10.1016/j.cirpj.2025.04.003","DOIUrl":"10.1016/j.cirpj.2025.04.003","url":null,"abstract":"<div><div>The rapid increase in air traffic and the growing focus on more sustainable solutions require improvements in fuel efficiency and cost reduction, highlighting the importance of lightweight materials in aircraft manufacturing. This study investigates the one-up drilling process of Carbon Fibre Reinforced Polymer and AA7075-T6 stack, focusing on the influence of process parameters, drilling boundary conditions and clamping force on the hole quality. A robotic drilling system was used to study both ideal and non-ideal boundary conditions. Under ideal boundary conditions, optimal drilling parameters were identified: a cutting speed of 85 m/min and a feed rate of 0.01 mm/rev for CFRP, and 60 m/min with 0.05 mm/rev for AA7075-T6. Therefore, parameter switching strategies were implemented to improve hole quality at the material transition zone. Then, under non-ideal boundary condition, variable clamping forces (0 N, 250 N, and 400 N) were applied by the robot's end effector, demonstrating that higher clamping forces significantly reduce interlayer gaps, leading to up to 60.27 % reduction in entry burr and 16.10 % decrease in delamination factor. This comprehensive approach provides deeper understanding on how process parameters and boundary conditions affect both hole quality and tool forces, offering new insights for optimising drilling processes in aerospace manufacturing.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 1-14"},"PeriodicalIF":4.6,"publicationDate":"2025-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143839768","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}