CIRP Journal of Manufacturing Science and Technology最新文献

{"title":"Step-dependent machining uncertainty modeling for the process route and application in the machining of the ring-gear","authors":"Yanan Zhao,&nbsp;Shaoming Yao","doi":"10.1016/j.cirpj.2025.09.011","DOIUrl":"10.1016/j.cirpj.2025.09.011","url":null,"abstract":"<div><div>This paper proposes a step-dependent machining uncertainty modeling method for the process routes. With the between-step interaction, the process route integrity is accurately interpreted and all error sources in the production environment are involved in, including the workpiece positioning surface, machine positioning surface, cutter kinetics, workpiece kinetics, clamping force, cutting force, environmental factors, residual stress distortion, heat treatment distortion, and coating/plating variations. The machining uncertainty model shows that the machining uncertainty consists of both regenerated and inherited uncertainties. The proposed modeling method can evaluate a process route in terms of its error source impact on workpiece accuracy. A herringbone gear ring is used to demonstrate its effectiveness as a case study, where an uncertainty model is developed for the full process route, and the process route is assessed before the costly process trial. The process number is reduced from 18 to 15 without affecting the final workpiece accuracy. The experiment shows a good agreement with the uncertainty model results.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 170-184"},"PeriodicalIF":5.4,"publicationDate":"2025-09-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145120881","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":"Modelling of abrasive particle distribution for pre-mixed abrasive water jet peening surface","authors":"Zhao Wang ,&nbsp;Xiaowen Rong ,&nbsp;Haoran Zhao ,&nbsp;Yue Yang ,&nbsp;Fusheng Liang ,&nbsp;Cheng Fan","doi":"10.1016/j.cirpj.2025.09.010","DOIUrl":"10.1016/j.cirpj.2025.09.010","url":null,"abstract":"<div><div>Abrasive water jet technology, as a non-traditional machining process, impinges on the workpiece surface with abrasive particles driven by the water jet beam to achieve material removal or surface modification. The abrasive particle distribution is the key factor affecting on the process quality, especially for Abrasive Water Jet Peening (AWJP) process. However, there is still limited research on the abrasive particle distribution in the AWJP process, especially regarding the distribution under variable traverse speeds and variable curvature movements of the abrasive water jet beam, which forms the basis for controlling abrasive water jet coverage, particularly on curved surfaces. In this study, an abrasive particle distribution prediction model is proposed for AWJP under different pump pressures, variable traverse speeds (accelerations), and various curvature radius by combining finite element and analytical modeling approaches. Validation experiments were conducted, and both simulation and experimental results under different parameters follow Gaussian distributions. The maximum prediction error was only 18.6 % across 24 comparisons from 15 experimental sets, confirming the feasibility and accuracy of the proposed model. Meanwhile, the influence of these three parameters on abrasive particle distribution laws is investigated respectively through comparisons between simulation and experimental results. The findings reveal that pump pressure primarily affects abrasive particle velocity and position distribution; traverse speed mainly influences abrasive particle position distribution and the percentage of particles at the central region; curvature radius predominantly affects the midline position of the abrasive particle distribution curve. This study not only provide a deep understanding of abrasive particle distribution laws under varying pump pressures, traverse speeds, and curvature radii, but the proposed model also offers valuable guidance for achieving uniform abrasive particle coverage on free-form surfaces during AWJP.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 135-155"},"PeriodicalIF":5.4,"publicationDate":"2025-09-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145108138","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":"Research on the deformation mechanism for current-assisted splitting spinning forming of small-module gear-shaped parts with extreme diameter-to-module ratios","authors":"Qinxiang Xia ,&nbsp;Haoyang Zhou ,&nbsp;Gangfeng Xiao ,&nbsp;Sizhu Cheng ,&nbsp;Junhao Zhang","doi":"10.1016/j.cirpj.2025.08.012","DOIUrl":"10.1016/j.cirpj.2025.08.012","url":null,"abstract":"<div><div>Small-module gear-shaped parts (SMGSPs, module <em>m</em> &lt; 1) with extreme diameter-to-module ratios (<em>D</em>/<em>m</em>&gt;100) are critical components in miniature precision systems for spatial transmission and lightweight structural applications. However, it exhibits restricted fatigue strength and excessive material wastage when manufactured by conventional machining processes. A novel current-assisted splitting spinning forming (CASSF) method combining the precision of spinning technology with the electroplastic effects of pulsed current synergistically was proposed to realize the high-performance near-net shape forming of SMGSPs. A finite element model coupled with the electroplasticity effect is constructed. Finite element model (FEM) simulations and experimental studies systematically investigated the distribution of the electric field, temperature field, the equivalent stress and strain, and the dynamic material flow of small module gears during CASSF. The results revealed that the current density of the SMGSP is concentrated near the contact area of the roller, so the softening region, due to the electroplasticity effect, highly overlaps with the deformation region of the SMGSP. The gear profile deformation exhibits a non-uniform stress-strain distribution, with peak stress concentrations localized at the exit-side tooth root arc. The application of pulsed current effectively reduced equivalent stress and enhanced material deformability, achieving saturation thresholds at 17.5 A/mm² current density (<em>J</em>_p) and 40 % duty ratio (<em>d</em>). Five distinct material flow orientations develop during CASSF, forming four flow division surfaces between them. The uneven tooth height defect originates from asymmetric material flow between the entry and exit sides, whereas tooth underfilling stems from insufficient axial material flow. A forward-reversed forming strategy with intensified pulsed current eliminated tooth height discrepancies and improved tooth saturation (<em>γ</em>) to 97.8 %, demonstrating the potential of CASSF potential for forming extreme ratio SMGSPs.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 116-134"},"PeriodicalIF":5.4,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145107773","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":"Gaussian process-based surrogate framework for efficient prediction of geometrical inaccuracy in Wire Electrical Discharge Machining of thin-wall miniature components","authors":"Aswin P.,&nbsp;Rakesh G. Mote","doi":"10.1016/j.cirpj.2025.09.006","DOIUrl":"10.1016/j.cirpj.2025.09.006","url":null,"abstract":"<div><div>High aspect ratio, thin-walled miniature structures are critical in applications such as microfluidics and micromechanical cooling. Wire Electrical Discharge Machining (Wire EDM) presents a commercially viable alternative to specialized micromachining setups for fabricating such features. However, as part size decreases, conventional Wire EDM faces challenges in achieving accurate profiles due to intensified thermal effects and reduced part stiffness, leading to increased geometrical errors. To address this, a reduced-order surrogate framework based on Gaussian Process Regression (GPR) is developed to predict key geometrical deviations specifically, reduced wall thickness and wall deformation as functions of process parameters. The framework integrates four GPR models trained on hybrid datasets combining experimental data and physics-based numerical results. A discrepancy model further refines numerical predictions by accounting for deviations from experimental data. The final GPR models achieve mean absolute errors of 3.39 <span><math><mi>μ</mi></math></span>m and 6.08 <span><math><mi>μ</mi></math></span>m for wall thickness and deformation, with <span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span> values of 0.96 and 0.99. K-fold cross-validation and validation experiments confirm model reliability, with prediction errors around 14.3 <span><math><mi>μ</mi></math></span>m and 12.1 <span><math><mi>μ</mi></math></span>m. The discrepancy model reduces the deviation of numerical predictions from actual values by 55%. Process parameter optimization is performed to fabricate thin walls with targeted deformation levels, achieving reasonable accuracy within 22.3 <span><math><mi>μ</mi></math></span>m. Furthermore, sensitivity analysis is conducted to quantify both individual and interactive influences of major process parameters on geometrical errors.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 97-115"},"PeriodicalIF":5.4,"publicationDate":"2025-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145107772","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":"Characterization of the friction behavior of wrought and hot isostatic pressed laser powder bed fusion Ti6Al4V alloys","authors":"Necati Uçak ,&nbsp;Kubilay Aslantas ,&nbsp;Adem Çiçek ,&nbsp;José Outeiro","doi":"10.1016/j.cirpj.2025.09.007","DOIUrl":"10.1016/j.cirpj.2025.09.007","url":null,"abstract":"<div><div>This paper presents determination of the friction coefficients and an analysis of the frictional behavior of wrought and hot isostatic pressed Laser Powder Bed Fusion (LPBF) Ti6Al4V alloys against uncoated cemented carbide (WC-Co) under conditions that simulate those encountered in metal cutting. For this purpose, a series of pin-on-bar tribological tests were performed in an open tribometer configuration at a high average contact pressure (∼1.5 GPa) and different sliding speeds (9.58–38.3 m/min) under dry conditions. The tests permitted to determine sliding speed dependent apparent friction coefficients (<em>μ</em>_<em>app</em>) between WC-Co pins and wrought/LPBF Ti6Al4V bars. A 3D model of the tribological test was developed for the purpose of obtaining the adhesive friction coefficients (<em>μ</em>_<em>adh</em>) through the post-processing of the test data of <em>μ</em>_<em>app</em>. The tribological behavior was evaluated in terms of the friction coefficient, the build-up material (adhesion) to the pin, surface topography, and subsurface microstructure. The test results showed that wrought and LPBF Ti6Al4V alloys have a different tribological behavior. The <em>μ</em>_<em>app</em> exhibited a range of values for the wrought Ti6Al4V alloy spanning from 0.458 to 0.327, while the LPBF Ti6Al4V alloy demonstrated a slightly different range, from 0.499 to 0.251, depending on the sliding speed. At high sliding speeds, the wrought material exhibited higher adhesion volumes on the pins, as well as higher friction coefficients and a greater deformation zone thickness in comparison to the LPBF Ti6Al4V alloy. The <em>μ</em>_<em>adh</em> values obtained for both the wrought and LPBF Ti6Al4V alloys can be employed in the modelling and simulation of metal cutting operations.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 83-96"},"PeriodicalIF":5.4,"publicationDate":"2025-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145108136","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":"Bottom-up segmentation of composite structures for cost-efficient manufacturing","authors":"Ádám Ipkovich ,&nbsp;Alex Kummer ,&nbsp;Balázs Fodor ,&nbsp;Gergely Erdős ,&nbsp;László Takács ,&nbsp;János Abonyi","doi":"10.1016/j.cirpj.2025.08.011","DOIUrl":"10.1016/j.cirpj.2025.08.011","url":null,"abstract":"<div><div>This work focuses on optimizing manufacturing processes for composite products with complex geometry. The goal is to efficiently partition the 3D surface mesh so that parts can be manufactured with specific technologies while minimizing costs. For this purpose, the proposed algorithm merges the elementary units iteratively by selecting the two elements that reduce the total cost through a bottom-up hierarchical clustering algorithm. The applicability of the method is demonstrated in a case study of bus manufacturing. The results illustrate how the costs of tools, adhesives, and materials vary when a complex structure is segmented.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 71-82"},"PeriodicalIF":5.4,"publicationDate":"2025-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145108137","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 additive manufacturing of a bimodal laminate heterostructure with Cu-base and Ni-base alloys","authors":"Liming Yan ,&nbsp;Bo Li ,&nbsp;Jianrui Zhang ,&nbsp;Fuzhen Xuan","doi":"10.1016/j.cirpj.2025.09.009","DOIUrl":"10.1016/j.cirpj.2025.09.009","url":null,"abstract":"<div><div>A bimodal laminate heterostructure consisting of alternating copper-base (CuCrZr) and nickel-base (Hastelloy X) alloy layers was carefully fabricated via multi-material laser powder bed fusion (MM-LPBF) additive manufacturing approach, employing a custom-designed multi-powder delivery device system and proprietary process-control software. The heterostructure shows a hierarchical architecture with periodically alternating coarse-grained (predominantly Hastelloy X) and fine-grained (primarily CuCrZr) layers, interconnected by transition zones containing mixed grain morphologies. The heterostructural material demonstrates exceptional mechanical performance under building-direction loading, achieving a yield strength of 674.2 MPa, ultimate tensile strength of 756.4 MPa (∼92 % of monolithic LPBF-processed Hastelloy X), and elongation of 19.9 %. Crystal plasticity simulations elucidate deformation coordination and strength-ductility synergy mechanisms, while microstructural characterization confirms the bimodal grain structure originates from the LPBF-laser-induced melt pool dynamics and heterogeneous nucleation during the rapid solidification. This study establishes MM-LPBF as a viable approach for manufacturing high-performance, architecturally graded multi-material systems.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 58-70"},"PeriodicalIF":5.4,"publicationDate":"2025-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145050313","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":"Influence of non-planar orientations on solidification microstructure during robot-assisted laser-wire directed energy deposition","authors":"Sumitkumar Rathor ,&nbsp;Dhruva Kumar Goyal ,&nbsp;Ravi Kant ,&nbsp;Ekta Singla","doi":"10.1016/j.cirpj.2025.09.002","DOIUrl":"10.1016/j.cirpj.2025.09.002","url":null,"abstract":"<div><div>This work investigates the effect of temperature gradient on the solidification morphology during the non-planar laser-wire directed energy deposition (LWDED) process, abbreviated as DED-LB/w according to ISO/ASTM 52900:2021 standard. The LWDED abbreviation is used further in this work. The novelty of this study lies in the independent variation of substrate tilt angle (STA) and wire feed angle (WFA), which presents a comprehensive understanding of non-planar depositions. The temperature distribution and solidification parameters were computed using a customized 3D transient heat transfer model. This numerical model was introduced considering the pulsed laser beam, laser spot shape and size change due to different non-planar orientations. Solidification time, microstructural changes, and heat-affected zone (HAZ) morphology were discussed by correlating the stainless steel 316 L temperature distributions. A numerical and experimental analysis was presented for single-layer deposits. The STA and WFA significantly influence the cooling rates during solidification, affecting the microstructure of the beads. Lower STA (0°-15°) and WFA (10°-20°) result in higher cooling rates. The change in the laser beam spot size affects the solidification rate in the tilt direction due to the lower heating concentration. Smaller WFA (10°-20°) enables the wire to be positioned closer to the molten pool. It results in better energy absorption and efficient melting by increasing temperature. It increased the initial temperature difference and cooling rate. The fraction of equiaxed solidification morphology from the centre to the tilt direction increased with a reduced thermal gradient. The main outcome of this work is the validated solidification map for non-planar LWDED for optimizing deposition strategies in supportless additive manufacturing. The present approach will help suggest the deposition orientations to achieve consistent quality and reliability in deposited parts at non-planar orientations. This work is required to decide deposition strategies for supportless additive manufacturing.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 43-57"},"PeriodicalIF":5.4,"publicationDate":"2025-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145050315","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":"Silver streaks dependence on processing conditions in the injection molding of post-consumer recycled polypropylene","authors":"Anna Bortoletto,&nbsp;Andrea Orfano,&nbsp;Marco Sorgato,&nbsp;Giovanni Lucchetta","doi":"10.1016/j.cirpj.2025.09.005","DOIUrl":"10.1016/j.cirpj.2025.09.005","url":null,"abstract":"<div><div>The growing emphasis on sustainability in plastic waste management has driven interest in recycled polymers, including post-consumer recycled polypropylene. A critical challenge in this field is achieving satisfying aesthetic surface quality in molded components, particularly when defects such as silver streaks arise. This study explores the influence of injection molding processing parameters on the physical and chemical mechanisms underlying defect formation, with a focus on the role of volatile organic compounds released from the degradation of residual inks and binders. Results reveal that silver streaks are significantly influenced by melt temperature, shear rates, and injection speed. These findings not only improve our understanding of how silver streaks form but also suggest practical ways to improve the quality of recycled polypropylene products by adjusting process parameters.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 1-11"},"PeriodicalIF":5.4,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145050314","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":"An analytical elastic-plastic contact model for process damping prediction in milling","authors":"Yan-Ru Jiang,&nbsp;Xiao-Jian Zhang,&nbsp;Ke-Yan Chen,&nbsp;Si-Hao Mao,&nbsp;Han Ding","doi":"10.1016/j.cirpj.2025.09.004","DOIUrl":"10.1016/j.cirpj.2025.09.004","url":null,"abstract":"<div><div>Process damping is mainly caused by the dynamic extrusion between the flank face of the tool and the wavy machined surface of workpiece. An accurate description of process damping is critical for predicting stability and optimizing chatter-free cutting parameters. Existing process damping models neglect the extrusion deformation state in the indentation force calculation, and thus cannot reveal the dynamic deformation behavior of the extrusion. This paper presents a general analytical process damping model based on the elastic-plastic contact deformation. The proposed model analyzes three stages of contact deformation, i.e. the elastic regime, mixed elastic-plastic regime, and fully plastic regime, and calculates the indentation force separately for each stage, which avoids additional coefficient identification. Then, the equivalent viscous damping is derived from energy balance to linearize the indentation force and predict stability. The new model is validated by scratching tests and milling experiments, which can predict stability accurately and replace the traditional model.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 28-42"},"PeriodicalIF":5.4,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145050316","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}