CIRP Journal of Manufacturing Science and Technology最新文献

{"title":"Accuracy analysis and improvement methods for revolving parts in counter-rotating electrochemical machining with continuous radial feeding","authors":"Guowei Cui ,&nbsp;Dengyong Wang ,&nbsp;Zengwei Zhu ,&nbsp;Shuofang Zhou","doi":"10.1016/j.cirpj.2024.08.004","DOIUrl":"10.1016/j.cirpj.2024.08.004","url":null,"abstract":"<div><p>Counter-rotating electrochemical machining (CRECM) stands out as an efficient and cost-effective method for machining aero-engine casings. To maintain stability in the CRECM process equilibrium state, continuous feeding of the cathode tool is essential. However, this continuous feeding approach with single direction of rotation may result in poor roundness and reduced machining accuracy. This paper aims to analyze the sources and rules of roundness error and asymmetry in CRECM. Based on simulation results, a method involving periodic reverse rotation of electrodes with continuous feeding is proposed for CRECM. This approach aims to mitigate the cumulative machining error, thereby significantly improving machining accuracy. Experimental results validate the efficacy of the proposed method at a rotation speed of 0.2 rpm. The roundness error is markedly reduced from 0.19 mm to 0.04 mm, resulting in a more symmetric convex structure. Additionally, the sidewall taper angle is reduced from 14.5 degrees to 6.4 degrees. This underscores the effectiveness of the proposed method in enhancing machining accuracy.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"54 ","pages":"Pages 43-56"},"PeriodicalIF":4.6,"publicationDate":"2024-08-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142041151","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":"Effect of process parameters on the mechanical properties of wires produced from A356 aluminum alloy chips by Continuous Friction Stir Extrusion: Experiments and numerical simulation","authors":"Simone Amantia,&nbsp;Davide Campanella,&nbsp;Riccardo Puleo,&nbsp;Gianluca Buffa,&nbsp;Livan Fratini","doi":"10.1016/j.cirpj.2024.08.001","DOIUrl":"10.1016/j.cirpj.2024.08.001","url":null,"abstract":"<div><p>Recycling of metals is becoming crucial from an economic and environmental point of view. The solid-state recycling process Continuous Friction Stir Extrusion was used to produce wires out of A356-T6 chips. The mechanical properties of the produced wires were explored by varying the main process parameters. Characterization involved Vickers hardness tests, tensile tests, grain size measurements, and fracture surface analysis. It has been found that it is possible to achieve 77 % of the Ultimate Tensile Strength (UTS) and 92 % of Vickers hardness with respect to the as-fabricated A356 alloy. The average grain size increases with the tool rotational with values ranging from about 9 µm to about 11 µm. A 3D dedicated numerical model was used to predict the distributions and histories of primary field variables, and to calculate the Piwnik-Plata parameter, fostering a more in-depth understanding of the process mechanics. This allows for the precise prediction of unacceptable product quality of the bonding when the Plata and Piwnik parameters are low. Predicted temperature close to the rotating tool should reach 400 °C while the cochlea temperature should be below 100 °C for sound wires production thus avoiding early chip bonding and process failure.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"54 ","pages":"Pages 28-42"},"PeriodicalIF":4.6,"publicationDate":"2024-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142011091","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 circumferential distance location of the laser energy beam in the laser-assisted turning of Al/SiC metal matrix composites","authors":"Edo Suryo Pratomo,&nbsp;Paul Mativenga,&nbsp;Lin Li","doi":"10.1016/j.cirpj.2024.08.002","DOIUrl":"10.1016/j.cirpj.2024.08.002","url":null,"abstract":"<div><p>Laser-assisted turning (LAT) involves locally heating a rotating workpiece using a focused laser beam before the removal of material. A key aspect in optimising productivity with laser-assisted turning is understanding the thermal relationship between laser heating, the improved material removal rate, and machinability. Consequently, in this paper, a thermal heating and laser-assisted turning finite element model and experiments were conducted to assess the machinability of an Al/SiC_p MMC workpiece, considering the circumferential location of the laser beam from the cutting point. The results confirm that laser power and cutting velocity influence the temperature profile from the laser spot to the tool point and the heat-affected depth. Positioning the cutting tool closer to the laser spot effectively reduces the Von Mises stress during cutting at higher cutting temperatures. At the same time, the experiment indicates an increased risk of directly heating the tool, which can affect the integrity of the cutting tool. The work further reveals that at specified cutting velocities, lower specific cutting energy improves the tool condition and surface quality of the machined parts. Based on a range of material removal rates and laser-specific energy density, a new criterion for optimal laser-tool circumferential distance was determined. Establishing this distance can act as a guide for the laser-assisted turning of Al/SiC_p metal matrix composites and potentially other materials.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"54 ","pages":"Pages 14-27"},"PeriodicalIF":4.6,"publicationDate":"2024-08-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S1755581724001202/pdfft?md5=799f1554b106c990058fa87cc0aa6f7d&pid=1-s2.0-S1755581724001202-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141992906","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"On the effect of material density in dimensional evaluations by X-ray computed tomography of metal-polymer multi-material parts","authors":"Daniel Gallardo ,&nbsp;Lucía-Candela Díaz ,&nbsp;Filippo Zanini ,&nbsp;José Antonio Albajez ,&nbsp;Simone Carmignato ,&nbsp;José A. Yagüe-Fabra","doi":"10.1016/j.cirpj.2024.08.003","DOIUrl":"10.1016/j.cirpj.2024.08.003","url":null,"abstract":"<div><p>An important aspect to consider in the evaluation of parts and assemblies by X-ray computed tomography (XCT) is the attenuation coefficient of the different materials involved, which are directly related to their density; depending on this coefficient, the X-ray penetration varies and, therefore, varies the contrast between different materials and with the background. This becomes more critical in those assemblies in which materials are characterized by a high difference in density, where the lighter material could be difficult to be characterised. In this paper, the effect of the presence of metals in the dimensional evaluation of polymeric geometries (having lower density than the metal parts) is studied, to evaluate the errors caused in dimensional measurements of different geometries and surface texture characterization. Based on a common geometry, four scenarios have been experimentally tested with variations of metal amount, in which macro geometries (precision spheres made by different polymers) and micro geometries (inclined ramps manufactured by fused deposition modelling (FDM)) have been characterised. Results show errors in the surface determination of the polymeric features directly related to the presence of metal: a high amount of steel makes significantly difficult to accurately determine the interface between background and material due to the noise and artifacts created, while aluminium has less influence on the irregularities of the features extracted. This effect is more evident for polymers with lower density due to the higher difference. Numerically, most affected parameters are those sensible to variations in surface determination, such as spheres’ form error and ramps’ maximum surface texture (<em>Sz</em>), while more solid features as spheres’ diameters, distances and ramps’ average surface texture (<em>Sa</em> and <em>Sq</em>) remain more stable. In conclusion and to sum up, it has been found that the quantity of metal present in assemblies made of polymeric and metallic materials is correlated with distortions in the dimensional evaluation of polymeric features by XCT.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"54 ","pages":"Pages 1-13"},"PeriodicalIF":4.6,"publicationDate":"2024-08-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S1755581724001196/pdfft?md5=08600a1a0dedf0ec67759a6222a61f32&pid=1-s2.0-S1755581724001196-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141979406","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of the boriding thermal cycle of a cladded Inconel 718 layer on both in situ age hardening as well as wear and corrosion behavior","authors":"Richard Müller ,&nbsp;Philipp Hengst ,&nbsp;Horst Biermann ,&nbsp;Ralph Hunger ,&nbsp;Robin Berger ,&nbsp;Anja Buchwalder","doi":"10.1016/j.cirpj.2024.07.007","DOIUrl":"10.1016/j.cirpj.2024.07.007","url":null,"abstract":"<div><p>Nickel-based superalloys exhibit exceptional suitability for operating in environments characterized by corrosive agents and elevated temperatures. Strategic allocation of this expensive material solely to the functional surface areas yields significant economic advantages. The poor tribological property profile of Inconel 718 can be significantly improved through a boriding process. In this study, the possibility of combining a coating process with boriding technology and in situ heat treatment was investigated. Layers of Inconel 718 were deposited to an austenitic stainless steel using wire-based electron beam cladding (EBC) and subsequently subjected to boriding. Based on results from annealing experiments, boriding treatments were performed at various temperature/time regimens with the aim of inducing in situ age hardening during boriding. The focus was on the investigation of the influence of the temperature/time regime during boriding on the microstructure and hardness, as well as examining the wear and corrosion behavior of the resulting borided layers. The results showed that the desired target hardness range was achieved after in situ aging with all boriding variants. Furthermore, it was demonstrated that boriding significantly improved the wear resistance but decreased corrosion resistance.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"53 ","pages":"Pages 118-127"},"PeriodicalIF":4.6,"publicationDate":"2024-07-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S1755581724001160/pdfft?md5=bee02b477fd7939d8dc46626229f2d31&pid=1-s2.0-S1755581724001160-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141961423","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"View planning in the visual inspection for remanufacturing using supervised- and reinforcement learning approaches","authors":"Jan-Philipp Kaiser ,&nbsp;Dominik Koch ,&nbsp;Jonas Gäbele ,&nbsp;Marvin Carl May ,&nbsp;Gisela Lanza","doi":"10.1016/j.cirpj.2024.07.006","DOIUrl":"10.1016/j.cirpj.2024.07.006","url":null,"abstract":"<div><p>Visual inspection in remanufacturing, despite technological progress, is still mainly performed by humans. A rough assessment of the product’s general condition and the dedicated inspection of individual product features or defects is necessary to identify the typically unknown product variant and assess the reusability of a used product and its components. Therefore, a system for automated visual inspection must be flexible and runtime-adaptive, as defects to be inspected in detail may occur anywhere on the product. In the present work, this problem is framed as a view planning problem solved by means of supervised learning and reinforcement learning using a specially developed simulation environment. Three variants of neural networks (PointNet, PointNet++, and Point Completion Network) are compared in the supervised learning case, whereas a deep learning SAC algorithm using the Point Completion Network as network structure is evaluated in the reinforcement learning case. Considering the specific boundary conditions prevailing in remanufacturing, the results are obtained from the use case of electric starter motor remanufacturing. The results show that supervised learning and reinforcement learning are suitable for determining the poses of an acquisition system at system runtime to react to an initially unknown inspection task. Our proposed framework is available open source under the following: <span><span>https://github.com/Jarrypho/View-Planning-Simulation</span><svg><path></path></svg></span>.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"53 ","pages":"Pages 128-138"},"PeriodicalIF":4.6,"publicationDate":"2024-07-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S1755581724001159/pdfft?md5=148540d1b66984095ee9873d38d8afae&pid=1-s2.0-S1755581724001159-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141961424","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Numerical chip formation analysis during high-pressure cooling in metal machining","authors":"Eckart Uhlmann ,&nbsp;Enrico Barth ,&nbsp;Benjamin Bock-Marbach ,&nbsp;Jörg Kuhnert","doi":"10.1016/j.cirpj.2024.07.003","DOIUrl":"10.1016/j.cirpj.2024.07.003","url":null,"abstract":"<div><p>Most metal turning processes utilize cutting fluids. Despite extensive experimental and analytical studies, the mechanisms of chip formation under consideration of a cutting fluid are still not entirely understood. Due to fluid-structure interaction, simulating wet cutting processes for an extended duration has not been feasible. The primary objective of this study is to utilize a simulation approach to provide additional information about the wet chip formation process in contrast to measurement methods, with a view to drawing conclusions. As methodology the Finite-Pointset-Method (FPM) is employed to simulate the chip formation process for dry, flood and specifically high-pressure cooling conditions during machining of carbon steel C45 as well as nickel-based alloy Inconel 718. Due to the increased relative velocity between workpiece and cutting fluid with the use of high-pressure cooling compared to flood cooling, numerical stability issues are present. Initially, the modeling approach to handle high-pressure cooling conditions is described and validated by an impact test. Subsequently the cutting simulation model is presented in detail and verified by measurements. The simulation results of stress, temperature and plastic strain rate fields are used to elucidate the observed discrepancies between various cutting fluid strategies in detail. These findings suggest explanations for the high efficiency of high-pressure cooling such as a decline of hydrostatic stresses or activation of ductile damaging.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"53 ","pages":"Pages 103-117"},"PeriodicalIF":4.6,"publicationDate":"2024-07-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S1755581724001147/pdfft?md5=9973021ae3661fe6b56b6befffee4679&pid=1-s2.0-S1755581724001147-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141961422","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of chip breaker geometries on chip breaking behaviour during profile grooving","authors":"Berend Denkena,&nbsp;Benjamin Bergmann,&nbsp;Marita Murrenhoff","doi":"10.1016/j.cirpj.2024.07.005","DOIUrl":"10.1016/j.cirpj.2024.07.005","url":null,"abstract":"<div><p>Chip breakers are used in turning to improve chip breakage. In standard cutting inserts, they are pressed into the rake face before sintering. However, for specialized tools like profile grooving tools, this pressing is not possible. Instead, a laser preparation process can be applied after grinding the tool profile to create a diverse range of chip breaker geometries. The aim of this investigation is to gain insights into the relationship between the geometric parameters of laser-prepared chip breaker geometries and chip formation. For this reason, experimental turning investigations were conducted with varied chip breaker geometries. Based on these experiments, chip formation was observed for different profile geometries and chip breakers. The findings indicate that the inlet angle, outlet angle, width, depth, and lateral ridges significantly influence chip-breaking behaviour. These results can inform the development of application-specific design for chip breaker geometries.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"53 ","pages":"Pages 95-102"},"PeriodicalIF":4.6,"publicationDate":"2024-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S1755581724001135/pdfft?md5=201ca2104f11a11ad690f72fdf210121&pid=1-s2.0-S1755581724001135-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141949670","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental study on morphology, microstructure and mechanical properties of adjustable-ring-mode (ARM) laser welded Al-Mg alloy","authors":"Kai Guo ,&nbsp;Hongxi Jin ,&nbsp;Yanhong Wei ,&nbsp;Qingguo Wang ,&nbsp;Jicheng Chen","doi":"10.1016/j.cirpj.2024.07.004","DOIUrl":"10.1016/j.cirpj.2024.07.004","url":null,"abstract":"<div><p>Adjustable-ring-mode (ARM) laser welding displays great potential for improving the stability of the molten pool and the weld quality of aluminum alloys through the coaxial attachment of a large-sized ring-beam spot. In this paper, the author embarked on a systematic study on the impact of varied core powers, ring powers, and core/ring power ratios on the weld morphology, microstructure, and mechanical properties of Al-Mg alloy during the laser welding process with ARM. The results showed that the core power led to higher depth of penetration, and the superheating of the molten pool it created caused grain coarsening and reduced properties. The ring beam effectively decreased weld spatter and enhanced the surface roughness of the weld. Furthermore, the ring beam was more likely to obtain a wider columnar crystal zone and a more homogeneous grain size distribution. The welded joints possessed higher tensile strength values when ring beam power was increased from 1.5 to 2 kW due to the improvement of surface flatness and porosity defects by the ring beam.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"53 ","pages":"Pages 81-94"},"PeriodicalIF":4.6,"publicationDate":"2024-07-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141729700","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":"Microstructure and mechanical properties of additively manufactured Ti6Al4VxCryNi alloy","authors":"Pradyumn Kumar Arya,&nbsp;Neelesh Kumar Jain,&nbsp;Dan Sathiaraj","doi":"10.1016/j.cirpj.2024.07.001","DOIUrl":"10.1016/j.cirpj.2024.07.001","url":null,"abstract":"<div><p>This paper describes development of multi-layer deposition of Ti6Al4V added with 5 at% of Cr, 5 at% of Ni, and 2.5 at% of each Cr and Ni by μ-plasma powder arc additive manufacturing process. It presents findings on their microstructure, porosity, evolution of phases, microhardness, tensile strength, ductility, fracture morphology, fracture toughness, and abrasion resistance. Phase evolution found that α/α’-Ti and β-Ti phases are formed in all the alloys, intermetallic phase Cr₂Ti evolved in Ti6Al4V5Cr and Ti6Al4V2.5Cr2.5Ni alloys whereas intermetallic phase Ti₂Ni is formed in Ti6Al4V5Ni alloy. Their microstructure revealed that addition of chromium and nickel refined grains of their α-Ti and β-Ti phases. Elemental composition of the evolved phases found that at% of chromium, nickel, and vanadium in β-Ti phase is more than the α-Ti phase of the developed alloys. It enhanced their ultimate tensile and yield strength, and microhardness but reduced ductility. It changed the fracture mode from ductile to a combination of ductile and brittle mode possessing large size dimples, micropores, and cleavage facets. It is due to solid solution strengthening, evolution of intermetallic phases Cr₂Ti and Ti₂Ni, and grain refinement of β-Ti and α-Ti phases. Enhanced microhardness and presence of intermetallic phases improved fracture toughness and abrasion resistance of the developed alloys thus imparting them higher resistance to propagation of cracks and abrasive wear.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"53 ","pages":"Pages 67-80"},"PeriodicalIF":4.6,"publicationDate":"2024-07-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141638710","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}