CIRP Journal of Manufacturing Science and Technology最新文献

{"title":"Experiments on resistance spot welding of three layers of unequal thickness steel based on deep learning and multi-objective optimization","authors":"Haofeng Deng ,&nbsp;Pengyu Gao ,&nbsp;Honggang Xiong ,&nbsp;Xiangdong Gao","doi":"10.1016/j.cirpj.2025.07.005","DOIUrl":"10.1016/j.cirpj.2025.07.005","url":null,"abstract":"<div><div>Resistance spot welding (RSW) of three-layer steel sheets with unequal thicknesses presents significant challenges in accurately simulating weld nugget formation and process signal behavior. This paper proposes a hybrid approach that combines deep learning and multi-objective optimization to improve simulation accuracy. A 1D convolutional neural network (1DCNN), bidirectional long short-term memory (BiLSTM), and attention mechanism are integrated to predict dynamic resistance curves from process parameters. These predicted curves are then used as benchmarks in an ANSGA-II and Bayesian optimization framework to calibrate thermal-electrical contact parameters in a finite element model. Experimental results demonstrate that the optimized simulations closely match measured data, achieving a mean absolute error (MAE) of 0.132, a root mean square error (RMSE) of 0.156, and an <span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span> value of 0.91. The calibrated model reduces resistance prediction error by over 30% and improves nugget diameter and weld depth prediction accuracy across multiple thickness configurations. This integrated framework offers a practical and data-efficient solution for enhancing RSW simulations in complex multi-layer welding scenarios.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 497-512"},"PeriodicalIF":5.4,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144770728","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":"On the effect of nanosized Al2O3 on the mechanical properties and microstructural evolution during friction stir extrusion of AA 6082 aluminum chips","authors":"S. Emami ,&nbsp;G. Buffa ,&nbsp;M. Adnan ,&nbsp;B. Särnerblom ,&nbsp;V. Patel ,&nbsp;L. Fratini","doi":"10.1016/j.cirpj.2025.07.006","DOIUrl":"10.1016/j.cirpj.2025.07.006","url":null,"abstract":"<div><div>Friction stir extrusion (FSE), as a promising solid-state chip recycling technique, was employed to produce recycled wires from AA 6082 aluminum chips. Al₂O₃ reinforced and unreinforced wires with different tool rotations and vertical downforce were produced. The microstructure and texture evolution were studied using the electron backscattered diffraction (EBSD) technique. EBSD orientation maps showed that the microstructures developed a bimodal grain structure including fine recrystallized and non-recrystallized elongated grains. Grain orientation spread (GOS) EBSD maps demonstrated that the recrystallization was promoted in the presence of alumina second-phase nanoparticles. The resultant point-to-point and point-to-origin misorientation angle histograms indicated trivial misorientation differences proving the geometric dynamic recrystallization (GDRX) occurrence. The presence of loose high-angle grain boundaries (HAGBs) and accumulative misorientation angle inside the individual grains confirmed the continuous dynamic recrystallization (CDRX) occurrence. Moreover, grain boundary bulging was also visible through the microstructure, proving the activation of discontinuous dynamic recrystallization (DDRX). Texture analysis showed that simple a shear texture were introduced in the microstructure of the produced wires. The intensity of the obtained textures from the orientation distribution function (ODF) suggested that the application of the alumina particles improved the material flow during recycling. Micro-hardness measurements revealed that the addition of the alumina particles increased the hardness from 90 HV to 119 HV. Tensile testing showed a 20 % higher UTS for wires with alumina powders.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 485-496"},"PeriodicalIF":5.4,"publicationDate":"2025-07-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144721798","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":"The research of TRIZ-assisted additive manufacturing functional period construction process","authors":"Yunpeng Su,&nbsp;Guiru Wu,&nbsp;Zhen Liao,&nbsp;Xiaomeng Yan,&nbsp;Lanxin Jiang,&nbsp;Huan Qi","doi":"10.1016/j.cirpj.2025.07.007","DOIUrl":"10.1016/j.cirpj.2025.07.007","url":null,"abstract":"<div><div>Current research on additive manufacturing predominantly focuses on the structural and parameter levels, with relatively limited exploration on the functional level. This study investigates the construction process of the functional period in additive manufacturing by adapting the analysis and problem-solving tools from TRIZ theory at the functional level. First, the cyclic behavior of the additive manufacturing process is elucidated, followed by an analysis of the functional period embedded within the process. A classification method for complexity is introduced and the role of the functional period in transforming types of complexity is explained. Second, the analytic tools and problem-solving tools within TRIZ theory that are applicable to the additive manufacturing process have been summarized, leading to the establishment of functional solution acquisition paths specific to the additive manufacturing process. Third, based on these functional solution acquisition paths, a process model for constructing the functional period in additive manufacturing is proposed. Finally, the proposed functional period construction process model is applied to the porosity control of tin bronze samples. Experimental results demonstrate that the density of the tin bronze sample increased by over 4 %, confirming the feasibility of the TRIZ-assisted functional period construction process in additive manufacturing.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 474-484"},"PeriodicalIF":4.6,"publicationDate":"2025-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144711101","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":"Casting parts retrieval driven by the integration of process constraints and geometric features","authors":"Chuhao Zhou ,&nbsp;Shuren Guo ,&nbsp;Dong Xiang,&nbsp;Xuanpu Dong,&nbsp;Huatang Cao","doi":"10.1016/j.cirpj.2025.07.003","DOIUrl":"10.1016/j.cirpj.2025.07.003","url":null,"abstract":"<div><div>The formation of castings depends on numerous process parameters, making traditional casting process design heavily reliant on experience and complex calculations. Efficiently retrieving similar parts from a case library for process reuse can significantly enhance design efficiency. This study has proposed a tailored retrieval scheme for casting parts, ensuring that retrieved parts provide valuable references for process design. First, the study has introduced the concept of process constraint values to quantify the impact of differences in key semantic information—material, casting method, and production batch size—on the applicability and effective transferability of existing processes. These constraint values are incorporated as conditions in subsequent similarity calculations, ensuring that the retrieved parts offer practical reference value for casting process design. For geometric similarity measurement, simulation experiments and flowability analyses are conducted to evaluate the influence of volume and modulus on similarity computation. Considering the characteristics of casting production, shape-structure features are extracted from both the external solid model and internal cavity models. These features are then integrated into a combined encoding, providing a parametric representation of the part’s geometric characteristics. Finally, the overall geometric similarity between parts is simultaneously measured based on volume, modulus, and shape-structure feature encoding. The effectiveness of the proposed retrieval algorithm was validated using Expected Reciprocal Rank (ERR) and F1-score. Results indicate that the first highly similar part appeared at the 1.23th position in the ranked retrieval sequence, allowing users to efficiently find relevant parts at the top of the retrieval rankings. Furthermore, separating the feature extraction and similarity calculation of the external solid and internal cavity improves retrieval performance compared to direct feature extraction from the original part model, especially in high-relevance scenarios with few candidate results.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 443-462"},"PeriodicalIF":4.6,"publicationDate":"2025-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144687096","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":"The effects of laser assisted ultrasonic nanocrystal surface modification on 3D-printed Ti6Al4V alloy","authors":"Hao Zhang ,&nbsp;Yu Zhang ,&nbsp;Chang Ye ,&nbsp;Giovanna Rotella ,&nbsp;Domenico Umbrello","doi":"10.1016/j.cirpj.2025.07.004","DOIUrl":"10.1016/j.cirpj.2025.07.004","url":null,"abstract":"<div><div>This study investigates the synergistic effects of laser-assisted ultrasonic nanocrystal surface modification (LA-UNSM) on the surface integrity and microstructural evolution of 3D-printed Ti6Al4V alloy. By integrating localized laser heating (optimal power of 23 W) with ultrasonic peening, LA-UNSM significantly enhances material plasticity during treatment. As a result, compared to conventional UNSM, the process markedly improves surface finish, hardness, and compressive residual stress. Detailed analyses show that LA-UNSM refines the surface microstructure by reducing roughness (from 17.8 µm in as-fabricated samples to approximately 3.2 µm) and increasing hardness (from 359.5 HV to over 487.5 HV). Additionally, LA-UNSM promotes deeper plastic deformation, effectively reducing surface porosity and refining the grain size from an average of 1.1 µm to 0.53 µm. The treatment further modifies the crystallographic texture and slip behavior by favoring pyramidal 〈c+a〉 slip, which enhances strain accommodation and reinforces the compressive residual stress field. These findings demonstrate that LA-UNSM is a transformative, energy-efficient post-processing technique that substantially enhances the performance of additively manufactured Ti6Al4V alloys.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 463-473"},"PeriodicalIF":4.6,"publicationDate":"2025-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144687097","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":"Point projection-based contour-parallel tool path from point cloud","authors":"Yuning Zhang,&nbsp;Tong Xiao,&nbsp;Jinting Xu,&nbsp;Yuwen Sun","doi":"10.1016/j.cirpj.2025.06.009","DOIUrl":"10.1016/j.cirpj.2025.06.009","url":null,"abstract":"<div><div>Traditional reverse engineering (RE) often involves complicated and time-consuming CAD model reconstruction, which can be inefficient or unnecessary in practical scenarios focused on rapid shape replication and design validation. Therefore, a method is proposed in this paper for generating contour-parallel tool paths directly from point clouds, bypassing CAD model reconstruction, and it is particularly suited for parts with holes or island features. In this method, boundary points are first extracted and sequenced, and then boundaries are employed as initial tool paths to generate subsequent tool paths through successively offsetting. In the tool path offsetting, a novel point projection-based offsetting strategy is presented to calculate accurate cutter contact (CC) points in the neighbouring tool path, and the self-intersections appearing in offset CC paths are eliminated simultaneously. To simplify the offsetting operations, a simple merging strategy between the inner boundary and the generated offset tool path is presented to remove the undesired intra-intersections. Case studies demonstrate that the proposed method can nicely generate continuous and boundary conformal contour-parallel tool paths directly on point clouds with and without holes. Different from traditional CAD modelling, the proposed method provides a fast and efficient alternative for shape-oriented RE tasks.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 427-442"},"PeriodicalIF":4.6,"publicationDate":"2025-07-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144663519","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":"Investigations on the tooth surface deviations of internal whirling-enveloped TI worm","authors":"Zhenglin Yang,&nbsp;Yonghong Chen,&nbsp;Diao Chen,&nbsp;Wenjun Luo,&nbsp;Bingkui Chen","doi":"10.1016/j.cirpj.2025.07.002","DOIUrl":"10.1016/j.cirpj.2025.07.002","url":null,"abstract":"<div><div>Toroidal involute worm (TI worm) exhibits high load-bearing capacity and transmission efficiency. However, its complex spatial geometry complicates machining processes and limits mass production. This study combines the enveloping principle of the TI worm with the internal whirling technique. A novel method is developed for enveloping the TI worm via internal whirling. The influence of tool offsets and mounting angles on the tooth surface deviations between internal whirling-enveloped TI worm and standard TI worm is investigated. The results indicate that the tooth surface of the internal whirling-enveloped TI worm closely approximates that of modified standard TI worm. The amount and position of the modification can be effectively controlled through tool offset and mounting angle adjustments. Experimental measurements reveal a maximum tooth surface deviation below 0.04 mm. The machined worm meshes in the middle of the involute helical gear, reducing offset load risks. Comparative tests confirm comparable transmission performance between machined worm and standard TI worm. This study establishes theoretical and experimental foundations for mass production of TI worm via internal whirling to meet industrial demands.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 410-426"},"PeriodicalIF":4.6,"publicationDate":"2025-07-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144653404","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":"Reducing thermal errors with confidence: Uncertainty-based compensation for precision machine tools","authors":"Petr Kaftan ,&nbsp;Josef Mayr ,&nbsp;Florian Porquez ,&nbsp;Kévin Pomodoro ,&nbsp;David Trombert ,&nbsp;Konrad Wegener ,&nbsp;Markus Bambach","doi":"10.1016/j.cirpj.2025.06.001","DOIUrl":"10.1016/j.cirpj.2025.06.001","url":null,"abstract":"<div><div>This work presents a new probabilistic method for the compensation of thermal errors of precision machine tools. The basis of the proposed method is the Gaussian Process Regression (GPR) model combined with a threshold for the predicted standard deviation. The key advantage of the GPR model is that it not only provides point estimates for predictions but also quantifies the uncertainty associated with each prediction. Additionally, GPR combines the thermal error prediction and thermal key point selection into a single model, which considerably reduces the overall model complexity. Thermal errors are measured with the recently developed torque limit skip (TLS) thermal error measurement method for precision machine tools. When the applied threshold is exceeded, the model triggers a recalibration feedback loop using previously measured temperature and thermal error values measured with the TLS function. Results show that the self-recalibrating compensation model significantly reduces the thermal errors of the investigated machine tool.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 400-409"},"PeriodicalIF":4.6,"publicationDate":"2025-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144633422","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":"Multi-material laser powder bed fusion (MM-LPBF) additive manufacturing of dual-phase heterostructure steel","authors":"Guoqing Huang ,&nbsp;Hanlin He ,&nbsp;Bo Li","doi":"10.1016/j.cirpj.2025.07.001","DOIUrl":"10.1016/j.cirpj.2025.07.001","url":null,"abstract":"<div><div>The multi-material laser powder bed fusion (MM-LPBF) additive manufacturing technology enables the refined fabrication of artificially designed and spatially ordered integrated structures of multiple metallic materials. Through the screening of dissimilar material matching based on compositional similarity and metallurgical compatibility, three types of the bimetallic integrated bulk materials with heterostructures of staggered multi-layer planes, staggered multi-layer chessboards, and staggered multi-layer rotating gratings, respectively, were fabricated via the MM-LPBF using 316 L austenitic stainless steel and 18Ni300 martensitic steel powders as the raw materials. The printed bimetallic configurations present the dual-phase and bimodal structure of fine-grained martensite phase, with body-centered cubic (BCC) crystal structure, and coarse-grained austenitic phase, with face-centered cubic (FCC) crystal structure. The dual-phase regions exhibit spatially ordered distributions according to the artificial designs. The interfaces between the dual-phase regions display firmly bonded through the \"dual-phase interspersed and mixed\" transition form after melting-solidification from the laser molten pool behaviors. The characteristic geometric dimensions of these spatially arranged phase regions from differentiated geometric types vary from 200 to 500 µm, with dual-phase mixing zones of 100 µm width as the interfacial regions. Considering the strength-ductility synergy effect of the bimetallic integrated material of the austenitic and martensitic steels, the dynamic impact performances of the heterostructures under different impact strain rate conditions were experimentally verified, showing good impact resistances and energy absorption capacities of these dual-phase, bimodal, and hierarchical heterostructures. This MM-LPBF additive manufacturing path is conducive to the creation of more novel alloy systems with strength-toughness synergy using more integrated dissimilar metallic materials.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 386-399"},"PeriodicalIF":4.6,"publicationDate":"2025-07-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604596","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":"Study of cutting force of SiCp/Al composites based on acoustic-plasticity intrinsic model","authors":"ZhaoPeng Hao,&nbsp;XiaoHan Zhuang,&nbsp;YiHang Fan","doi":"10.1016/j.cirpj.2025.06.019","DOIUrl":"10.1016/j.cirpj.2025.06.019","url":null,"abstract":"<div><div>Ultrasonic vibration-assisted cutting (UVAC) is widely used in metal manufacturing due to its high-frequency acoustic energy benefits. However, constitutive models for UVAC of SiCp/Al composites often rely on the Johnson-Cook (JC) model, neglecting the ultrasonic-induced acoustic softening effect. To address this, we developed an acoustoplastic constitutive model for SiCp/Al by integrating dislocation density and crystal plasticity theories, incorporating stress superposition and acoustic softening. Using this model for cutting simulations and experiments, cutting forces were studied. The proposed acoustoplastic model's accuracy improvements in predicting UVAC cutting forces for SiCp/Al were systematically compared against the traditional JC model.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 368-385"},"PeriodicalIF":4.6,"publicationDate":"2025-07-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144580446","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}