CIRP Journal of Manufacturing Science and Technology最新文献

{"title":"Mechanism, calculation method, and analytical modeling of spindle thermal characteristics considering radiation heat transfer","authors":"Jun Yang ,&nbsp;Mengchao Wang ,&nbsp;Chao Wang ,&nbsp;Fei Li ,&nbsp;Yang Hui ,&nbsp;Shiqiao Liu ,&nbsp;Zheng Zhang ,&nbsp;Mohan Lei ,&nbsp;Jianwei Zhu","doi":"10.1016/j.cirpj.2025.06.012","DOIUrl":"10.1016/j.cirpj.2025.06.012","url":null,"abstract":"<div><div>Neglecting the effect of thermal dissipation by radiation heat transfer (RHT) in spindle system may lead to calculation errors in the finite element model and analytical model of temperature field and thermal errors. As a result, the actual temperature field and thermal error of the spindle cannot be truly characterized and the effectiveness of the compensation of the spindle based on the analytical model will be diminished. To address this issue, this article studies the heat dissipation mechanism of RHT of spindle system and proposes a Monte Carlo-Radiation Network Method (MC-RNM) for real-time calculation of net RHT in the spindle system during the operation of the machine tool. Then, the study proposes an improved thermal network method (I-TNM) to establish an analytical model for spindle temperature field and thermal error, taking into account RHT. It was also shown that the analytical model of the spindle taking into account RHT yields better accuracy and generalization in the calculations of temperature field and thermal error. Under different operating spindle conditions, the maximum error between the calculated steady-state temperatures at the left end face and lateral surface of the spindle and the experimental values is less than 0.4ºC. Additionally, the maximum error between the calculated steady-state thermal errors and experimental values is within 2 µm. The findings enhance the theoretical research on boundary conditions in precision spindle systems, providing theoretical support and guidance to advance the research investigating thermal structure design of the spindle and thermal error compensation.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 175-200"},"PeriodicalIF":4.6,"publicationDate":"2025-06-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144314569","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":"Impact of surface post-treatments on corrosion resistance in heat-treated laser-powder bed fused Nickel Aluminum Bronze","authors":"Khashayar Morshed-Behbahani,&nbsp;Nika Zakerin,&nbsp;Addison J. Rayner,&nbsp;Donald Paul Bishop,&nbsp;Ali Nasiri","doi":"10.1016/j.cirpj.2025.06.010","DOIUrl":"10.1016/j.cirpj.2025.06.010","url":null,"abstract":"<div><div>This study investigates the effects of surface finishing on the passive behavior and corrosion response of C63020- Nickel Aluminum Bronze (NAB) alloy produced via laser-powder bed fusion (L-PBF) additive manufacturing, followed by annealing. To evaluate these effects, annealed L-PBF NAB in its as-printed surface finish was compared to samples subjected to two different surface treatments: one ground and another ground followed by polishing. Microstructural analysis of the samples revealed primarily globular and elongated κ_III phase precipitates distributed within the α-Cu matrix. Surface roughness measurements ranked the samples from highest to lowest as: as-printed NAB, ground NAB, and polished NAB. The results revealed that rougher surfaces enhanced electrochemical performance, as NAB passivity is a time-dependent process that benefits from an increased effective surface area. As a result, the ground-only samples demonstrated the highest corrosion resistance among the evaluated conditions.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 153-162"},"PeriodicalIF":4.6,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144306572","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":"Microstructural evolution rule and prediction modelling of the surface layer during dry machining of AISI 9310","authors":"Tongyu Liu ,&nbsp;Wenxiang Zhao ,&nbsp;Lijing Xie ,&nbsp;Engao Peng ,&nbsp;Feinong Gao","doi":"10.1016/j.cirpj.2025.06.006","DOIUrl":"10.1016/j.cirpj.2025.06.006","url":null,"abstract":"<div><div>This paper studies the microstructural evolution rule of the surface layer created by dry turning of AISI9310 steel. In this study, a coupled model with preheated tools and the ALE (Arbitrary Lagrangian-Eulerian) method of finite element method (FEM) is established to verify the evolution rules. In order to complete the various parameters in the evolution rules, a series of tests are conducted, including thermal compression, cutting, and EBSD (Electron Back - scatter Diffraction) characterization. Based on the experimental results, a hot processing map is established to explore the grain refinement mechanism, and the critical strain condition is obtained by fitting with polynomials of different orders. Through comparison between the FEM and EBSD results, it is found that the evolution rules given in this paper can achieve a stable and uniform metallographic transformation layer and grain refinement layer, and they are consistent with the physical process of actual cutting, metal phase transformation and grain size evolution.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 163-174"},"PeriodicalIF":4.6,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144306571","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":"Hybrid wire arc directed energy deposition and machining approach for realizing density-based functionally graded materials with enhanced strength-to-weight ratios","authors":"Ritam Sarma ,&nbsp;Atul Singh Rajput ,&nbsp;Sajan Kapil ,&nbsp;Shrikrishna Nandkishor Joshi","doi":"10.1016/j.cirpj.2025.06.005","DOIUrl":"10.1016/j.cirpj.2025.06.005","url":null,"abstract":"<div><div><em>Wire Arc Directed Energy Deposition</em> (<em>WADED</em>), a high-deposition-rate <em>Additive Manufacturing</em> (<em>AM</em>) technique, enables the rapid fabrication of near-net-shape metallic components. However, achieving <em>Functionally Graded Materials</em> (<em>FGMs</em>) with density variations within the same material remains challenging. This study introduces a novel <em>Hybrid WADED</em> (<em>H-WADED</em>) process to fabricate mono-material FGMs with engineered density gradients tailored for applications in aerospace, nuclear energy, and electromagnetism. In this method, each layer is deposited using <em>WADED</em>, followed by face milling and robotic drilling to introduce controlled holes. The diameter and spacing of the holes are designed to achieve the desired density gradient, enabling up to a 10 % reduction in mass. Experimental results showed 2 mm diameter holes as optimal, minimizing material flow and distortion while improving the strength-to-weight ratio. This innovation also enhances thermal dissipation capabilities, making the components suitable for high-stress environments. Performance evaluation of the fabricated <em>FGMs</em> revealed a 26.2 % reduction in thermal conductivity and significant mitigation of residual stresses due to stress redistribution around the holes. Under compressive loading, the samples exhibited a maximum load capacity of 200 kN. Although tensile strength was reduced by 19.6 % compared to solid samples, elongation remained unaffected, highlighting the structural integrity of the components. This work demonstrates an effective method to fabricate density-based <em>FGMs</em>, providing a practical pathway for developing advanced, lightweight, and thermally efficient components for critical industrial applications.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 139-152"},"PeriodicalIF":4.6,"publicationDate":"2025-06-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144298359","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":"In-situ heat treatment via preheating and liquid cooling during high-speed coating of gears by directed energy deposition","authors":"Masaya Yokota ,&nbsp;Shiho Takemura ,&nbsp;Ryo Koike ,&nbsp;Teppei Maki ,&nbsp;Kazuhiro Takaki ,&nbsp;Takanori Mori ,&nbsp;Yoko Hirono ,&nbsp;Yasuhiro Kakinuma","doi":"10.1016/j.cirpj.2025.06.002","DOIUrl":"10.1016/j.cirpj.2025.06.002","url":null,"abstract":"<div><div>Automobile electrification has increased demand for higher-performance gears in drivetrains with specialized functional requirements beyond what conventional carburizing heat treatment can deliver. While carburizing is effective for mass production, it faces inherent limitations in achieving advanced material properties needed for next-generation applications. Therefore, this study proposes a high-speed coating method on rotational gear surfaces using directed energy deposition (DED). The proposed method can form the coating layer continuously and efficiently on the complex-shaped teeth of the gear, compared to the common method that forms coating along a complicated path matching the part’s geometry. Furthermore, a localized heat treatment system integrating laser preheating and liquid cooling is introduced to precisely control material characteristics of the coating layer. Experimental results demonstrate that this combined heat treatment achieves a crack-free, hard coating layer on preformed gears. This method shows significant potential for producing customized, high-performance gears for specialized applications in next-generation vehicles while reducing process complexity.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 114-127"},"PeriodicalIF":4.6,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144281076","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":"Optimization of clamping conditions in thin-walled part machining to minimize forced vibrations, part II: Dynamic updating of clamping force and location with position dependent dynamics","authors":"Rahmi Can Ugras,&nbsp;Yusuf Altintas","doi":"10.1016/j.cirpj.2025.05.014","DOIUrl":"10.1016/j.cirpj.2025.05.014","url":null,"abstract":"<div><div>Part I of the paper presents the identification of clamping locations and forces by considering the flexibility of thin-walled part at one tool location. Here, the effect of material removal and tool location in milling the flexible part is considered to minimize static and dynamic deflections. The optimization algorithm presented in Part I is computationally costly. Here, the changes in the stiffness and mass matrices are integrated into the optimization, and the clamping contact area is meshed with fewer elements, which reduces the computational load further. The method is validated in simulating the peripheral milling of a thin-walled cylindrical part with eightfold computational efficiency in comparison to the model presented in Part I.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 128-138"},"PeriodicalIF":4.6,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144281077","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":"Optimization of clamping conditions in thin-walled part machining to minimize forced vibrations, Part I: Model for the single tool –workpiece contact location","authors":"Rahmi Can Ugras,&nbsp;Yusuf Altintas","doi":"10.1016/j.cirpj.2025.05.015","DOIUrl":"10.1016/j.cirpj.2025.05.015","url":null,"abstract":"<div><div>Machining thin-walled, highly flexible parts is challenging due to excessive deflection, chatter, and forced vibrations, which can violate tolerance and surface finish requirements. These flexible parts are attached to the fixture or machine tool table using clamps. The location of the clamps and the clamping forces are usually selected intuitively in industry, although they affect the natural frequencies and magnitudes of the Frequency Response Functions (FRFs) of the part hence the deflections. This paper presents an algorithm to optimize the placement of clamps and the clamping forces to minimize static deflections and forced vibrations induced by milling forces at the fundamental tooth-passing frequency and its harmonics. The FRF at the tool-workpiece contact zone is calculated by analytically reducing the size of the full Finite Element (FE) model. The effect of clamping forces, and consequently the clamp stiffnesses, is considered in the model. It is shown that optimal clamping forces and clamp placements can lead to a reduction in both static deflections and forced vibrations. While this paper presents an optimal clamping condition model at a fixed tool path location, Part II extends the optimization to the entire tool path by considering the variation of workpiece dynamics caused by metal removal.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 103-113"},"PeriodicalIF":4.6,"publicationDate":"2025-06-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144262674","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":"A genetic algorithm-calibrated heat source model for reconstructing thermal history and precipitate evolution in additive friction stir multilayer deposition","authors":"Wancheng Lyu ,&nbsp;Xunzhong Guo ,&nbsp;Yizhou Shen ,&nbsp;Chunping Huang ,&nbsp;Fencheng Liu","doi":"10.1016/j.cirpj.2025.06.003","DOIUrl":"10.1016/j.cirpj.2025.06.003","url":null,"abstract":"<div><div>Additive friction stir deposition (AFSD) has shown significant potential for additive manufacturing of large structures, which involves unique thermal cycling effects in multilayer deposition. The present endeavor firstly attempts to develop a universal moving heat source model (the double-hump model) for finite element multilayer thermal simulation, which mathematically simplifies the non-uniform distribution of macroscopic heat flux densities in the deposition zone. By adopting a planar heat source formulation, the model consequently neglects the radial contribution of plastic dissipation. The main objective is to seek a convenient simulation means to reconstruct the thermal history of the multilayer deposition and to get its impact on the precipitate evolution and mechanical properties. The heat source model parameters were determined by a genetic algorithm based on the principle of monarch selection and uniform crossover strategy to match the experimental data. The temperatures predicted by the finite element model for the preheating and multilayer deposition stages agreed well with those obtained experimentally. The location of the maximum heat flux density in the deposition zone was evaluated for the first time. The simulation data and characterization results show that the simulation of the multilayer AFSD process based on the heat source model can effectively reflect the second phase evolution in the thermal cycle and the influence on the mechanical properties. Furthermore, this study presents a novel thermal analysis of distinctive phenomena occurring in the AFSD process, showing the potential of heat source modelling in the thermal simulation of multilayer deposition.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 70-87"},"PeriodicalIF":4.6,"publicationDate":"2025-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144239642","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":"Capability analysis of the dynamic R-test measuring thermo-elastic errors of a five-axis machine tool","authors":"Tae Hun Lee ,&nbsp;Tim Klinkhammer ,&nbsp;Daniel Zontar ,&nbsp;Christian Brecher","doi":"10.1016/j.cirpj.2025.05.011","DOIUrl":"10.1016/j.cirpj.2025.05.011","url":null,"abstract":"<div><div>Five-axis machine tools are essential in industrial applications for their ability to efficiently machine complex geometries with high accuracy. The challenge of maintaining accuracy over long machining times is exacerbated by thermal effects that can contribute to significant geometric errors. To analyze these thermally induced geometric errors, also known as thermo-elastic errors, it is first necessary to measure them. Since the thermo-elastic state of the machine can change within a few minutes, the measurement method must have a short measurement time and the capability to measure a large number of geometric errors simultaneously. A potential promising method is the dynamic R-test, which can record the displacements of the sensor nest on the tool center point, synchronized with the actual positioning of the axes during a dynamic movement, and calculate the geometric errors using a kinematic model. The feasibility of the data acquisition method was previously demonstrated, but not the precise analysis and validation of its capability. Therefore, this study analyses the capability of the dynamic R-test to measure thermo-elastic errors in practice considering the influence of method, machine tool, human and environmental measurement uncertainties. For this purpose, numerous relevant measurement uncertainties are quantified, and a comprehensive measurement uncertainty analysis is performed using the Monte Carlo method. The results are then used to optimize the measurement method, striking a balance between time efficiency, measurement uncertainty and the number of measurable errors. They are validated by an experimental study in which thermo-elastic errors are artificially generated using the CNC geometric error compensation function on a demonstrator machine and then measured. This demonstrates the capability of the optimized dynamic R-test to measure thermo-elastic errors in practical settings, as well as a practical approach to the measurement uncertainty analysis and implementation of the dynamic R-test for five-axis machine tools.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 88-102"},"PeriodicalIF":4.6,"publicationDate":"2025-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144255208","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":"Assessing sine and Gaussian fitting for surface feature extraction in real-time wear monitoring of turning operations","authors":"Muzaffer Tacettin Küllaç,&nbsp;Olkan Çuvalcı","doi":"10.1016/j.cirpj.2025.05.005","DOIUrl":"10.1016/j.cirpj.2025.05.005","url":null,"abstract":"<div><div>Due to the challenges in tool condition monitoring, sensor fusion systems and the search for supportive features have gained increasing attention. With advancements in image acquisition and processing, surface image features offer a low-cost, supplementary data source for monitoring applications. This study introduces two novel image features derived from the fitting error metrics of sine and Gaussian functions, applied to column projections of surface images. Unlike conventional texture analysis methods, this approach specifically targets the wave-like patterns characteristic of turned surfaces, enabling localized assessment of surface anomalies. Experiments were conducted with varying cutting speeds, feed rates, and depths of cut to investigate the correlation between the proposed features and tool wear. Static analysis yielded adjusted <span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span> values of 0.497 for sine fitting and 0.579 for Gaussian fitting, while dynamic analysis demonstrated higher correlations with adj. <span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span> values of 0.8007 and 0.8197, respectively. Additionally, a cropping analysis was implemented to address potential image acquisition challenges in real-world applications, such as optical distortions and debris interference. Results indicated that focusing on central regions improved static fitting accuracy by up to 28% and dynamic fitting accuracy by up to 16%, underscoring the robustness and practical applicability of the proposed features for localized wear analysis.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 51-69"},"PeriodicalIF":4.6,"publicationDate":"2025-06-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144240529","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}