CIRP Journal of Manufacturing Science and Technology最新文献

{"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}

{"title":"Theoretical model and experimental investigation of machined surface roughness considering plastic side flow","authors":"Baoyu Zhang ,&nbsp;Wenjun Deng ,&nbsp;Peixuan Zhong","doi":"10.1016/j.cirpj.2025.06.020","DOIUrl":"10.1016/j.cirpj.2025.06.020","url":null,"abstract":"<div><div>Plastic side flow in metal cutting significantly affects the machined surface quality, which is related to cutting parameters and tool geometry. Nevertheless, the existing studies mainly focus on its effects and causative factors in plastic deformation, missing in-depth research on the forming process and theoretical modeling. To establish an accurate surface roughness prediction model, this paper deeply analyzed the cutting process of 7075 aluminum alloy under different feed rates (<em>f</em>) and tool tip radii (<em>r</em>_<em>c</em>) based on the metal cutting principle and plastic side flow theory. The results suggested that the plastic side flow model proposed in this paper was consistent with the experimental results when <em>f</em> &lt; 0.1 mm/r and <em>r</em>_<em>c</em> &lt; 0.8 mm, and the increasing <em>f</em> and decreasing <em>r</em>_<em>c</em> were unfavorable to the plastic lateral flow. Additionally, the surface roughness prediction model matched with the actual experiments, with relative deviations ranging from 3.1 % to 9.8 %. The highest cutting surface quality (∼2 µm) was obtained at the preferred critical parameters (<em>f</em>= 0.5 mm/r and <em>r</em>_<em>c</em>= 0.4 mm). Cutting su<em>r</em>face formation was shown to be a competition result between plastic side flow, kinematic factors, and elastic recovery, whose coupled action determined the final surface. Consequently, this study proposed a surface roughness prediction model considering plastic side flow, offering guidance for cutting theory and practical production.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 353-367"},"PeriodicalIF":4.6,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144563507","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":"Ultrasonic assistance for fatigue properties improvement of AA6061/Ti6Al4V dissimilar joints by resistance spot welding","authors":"Mohan He ,&nbsp;Qian Wang ,&nbsp;Jinxiang Wang ,&nbsp;Ninshu Ma ,&nbsp;Yuanxun Wang","doi":"10.1016/j.cirpj.2025.06.004","DOIUrl":"10.1016/j.cirpj.2025.06.004","url":null,"abstract":"<div><div>Replacing monolithic Ti components with Al-Ti hybrid structures is a promising way to achieve lightweight design and cost reduction; thus, it is highly desirable to manufacture Al-Ti hybrid structures using appropriate welding techniques. In this study, the robust joining of AA6061 to Ti6Al4V was enabled by the in-situ ultrasonic-assisted resistance spot welding (UaRSW) technique. More importantly, the correlation between the interface microstructure and the quasi-static and fatigue fracture behaviors of the UaRSW joints was elucidated by comparing them with the corresponding conventional resistance spot welding (RSW) joints. Ultrasonic vibrations can enhance heat transfer to form thinner, wavy intermetallic compound (IMC) layers. Moreover, the oxide film on the surface of AA6061 fragmented under ultrasonic action and was distributed in the heat-affected zone (HAZ). Compared to RSW joints, UaRSW joints had a significantly higher tensile shear strength and energy absorption capacity, as well as much higher fatigue limits of 45 %. The transition from interfacial failure to button pullout was attributed to the UaRSW-induced wavy IMC layers, which inhibited crack propagation along the interface. This work demonstrated that in-situ ultrasonic-assisted UaRSW can effectively improve the joining quality while ensuring high productivity, which had great potential for high-performance Al-Ti welding.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 324-335"},"PeriodicalIF":4.6,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144518601","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":"Towards industrially relevant total variation based reconstruction of few-view computed tomography by exploiting noise level estimation","authors":"Maryam Bahrkazemi ,&nbsp;Alexander Rohde ,&nbsp;Jonathan Hess ,&nbsp;Sven Gondrom-Linke ,&nbsp;Patricio Guerrero ,&nbsp;Wim Dewulf","doi":"10.1016/j.cirpj.2025.06.008","DOIUrl":"10.1016/j.cirpj.2025.06.008","url":null,"abstract":"<div><div>To extend the applicability of in-line computed tomography (CT) within Industry 4.0, accelerating the data acquisition and image reconstruction process is essential to meet the demands of real-time, high-throughput inspection. This paper focuses on accelerating in-line CT by addressing the trade-off between image quality and angular sampling reduction through the development of dedicated reconstruction algorithms. Various inherent properties of in-line CT are leveraged as a priori knowledge, specifically the noise level, within a total variation (TV)-based reconstruction framework to enhance reconstruction quality, support automation, and enable accurate image analysis using 2%–5% of the data required by standard methods such as Feldkamp–Davis–Kress (FDK).</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 336-352"},"PeriodicalIF":4.6,"publicationDate":"2025-06-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144548889","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":"Design and performance study of a bionic damping boring bar based on the woodpecker","authors":"Jiyuan Tian ,&nbsp;Junli Li ,&nbsp;Gang Liu ,&nbsp;Jing Shi ,&nbsp;Yanji Wu","doi":"10.1016/j.cirpj.2025.06.011","DOIUrl":"10.1016/j.cirpj.2025.06.011","url":null,"abstract":"<div><div>Deep hole machining is a typical challenging process in the aerospace industry, where long overhang boring bars are prone to vibrations, resulting in poor surface quality, reduced tool life, and noise. To address the vibration issues in deep hole machining, this study proposes a bionic damping boring bar inspired by the woodpecker’s shock-absorbing head. The study first analyzes the structure of the woodpecker's head and establishes nonlinear vibration equation, which is solved using the Harmonic Balance Method (HBM). A preliminary bionic design of the boring bar was then proposed, consisting of two main structures: constrained-layer damping (CLD) shaft and bionic absorber. A three-stage biomimetic damping system was developed using metal, particulate materials, damping materials, and carbon fiber reinforced polymer (CFRP). A dynamic model of the boring bar is established to analyze the effect of structural parameters on amplitude response. Subsequently, particle swarm optimization (PSO) and orthogonal experiments are used to optimize the tool body and the bionic absorber. Finally, modal and cutting experiments are conducted, comparing the bionic damping boring bar with carbide boring bars. The results show that the bionic damping boring bar improves modal parameters and cutting stability. Compared to carbide boring bars, it has a 20 % higher natural frequency, 5 times higher damping ratio, and 1.7 times higher stiffness. At the same cutting depth, it provides smoother acceleration amplitude response in the time domain, lower harmonic amplitude in the frequency domain, and improved surface quality, resulting in higher machining accuracy.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 308-323"},"PeriodicalIF":4.6,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144491588","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":"Corrosion behavior and mechanical performance of AZ31/PEEK joints fabricated by Friction Stir Spot Joining and Self-Piercing Riveting","authors":"Junyi Chen ,&nbsp;Bin Wang ,&nbsp;Yulin Zhang ,&nbsp;Zeyu Zhang ,&nbsp;Qiuying Wei ,&nbsp;Wenliang Wu ,&nbsp;Junjie Chen ,&nbsp;Hongyan Zhang","doi":"10.1016/j.cirpj.2025.06.018","DOIUrl":"10.1016/j.cirpj.2025.06.018","url":null,"abstract":"<div><div>The progression of lightweight materials has introduced significant challenges in joining dissimilar substances such as magnesium alloys and polyether ether ketone (PEEK), particularly for demanding automotive and aerospace applications. This study systematically investigates the comparative performance of Friction Stir Spot Joining (FSpJ) and Self-Piercing Riveting (SPR), two promising techniques for fabricating magnesium-polymer dissimilar material (hybrid) joints. AZ31/PEEK joints were evaluated through detailed microstructural analysis (SEM with EDS), electrochemical corrosion testing (including electrochemical impedance spectroscopy and potentiodynamic polarization), and mechanical performance assessment via pull-out and tensile shear testing. The results show that FSpJ joints exhibited a substantially more positive self-corrosion potential and an ∼81 % reduction in corrosion current density compared to SPR joints during early immersion. Furthermore, FSpJ joints demonstrated superior corrosion resistance with a 10-fold higher charge transfer resistance (1.33 × 10² Ω·cm²) and a 57.8 % increase in initial tensile shear strength (4.13 × 10 ³ N) relative to SPR joints. However, following 192 h of immersion, FSpJ joints experienced a sharp reduction in shear strength (∼74.2 % loss), while SPR joints retained nearly double the residual strength of FSpJ joints, owing to the robustness of their mechanical interlocking design. These findings provide valuable guidance for material selection and joining techniques in the automotive and aerospace industries, where corrosion resistance and joint integrity are critical to ensuring long-term structural reliability in harsh service environments.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 296-307"},"PeriodicalIF":4.6,"publicationDate":"2025-06-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144480502","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-process feed-forward control approach of tubes and wire torsion in bending machines using VCSEL laser optical sensors","authors":"Enrico Simonetto,&nbsp;Andrea Ghiotti,&nbsp;Stefania Bruschi","doi":"10.1016/j.cirpj.2025.06.016","DOIUrl":"10.1016/j.cirpj.2025.06.016","url":null,"abstract":"<div><div>Elongated metal components, such as wires and tubes, are integral to numerous industrial applications, prominently including structural engineering, fluid transportation systems, and heat exchangers fabrication. Following their primary manufacturing phase, these components are typically wound into coils to streamline logistics and storage, necessitating a subsequent straightening phase prior to additional processing operations like bending, cutting, or expanding. The standard straightening technique involves passing the workpiece through multiple arrays of intentionally misaligned and skewed rollers. The axial displacement is conventionally measured using a downstream-mounted contact encoder. However, this approach frequently induces unintended torsional deformation, causing combined translation and rotation movements of the cross section. Precisely quantifying this rotational displacement is still challenging, and uncontrolled torsion can adversely impact the precision and quality of subsequent production stages. In response to these issues, this research introduces an innovative integrated in-process control methodology employing a VCSEL (Vertical-Cavity Surface-Emitting Laser) optical sensor. This advanced non-contact sensing technology enables simultaneous real-time monitoring of both axial displacement and rotational torsion, capturing component displacement data across two orthogonal axes at high sampling rates. Nonetheless, measurement accuracy is contingent upon multiple parameters, including the metallurgical characteristics of the component, measurement distance, sensor alignment accuracy, and the component’s transit speed. This study aims at identifying principal sources of measurement inaccuracies and proposes a targeted correction algorithm. Furthermore, alongside methodologies for robust calculation of both axial feed and rotational torsion are elaborated. Experimental validation through a representative case study confirms the system's efficacy, demonstrating reliable detection and control capabilities for torsional deviations below 1 deg over a 300 mm measurement span.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 268-276"},"PeriodicalIF":4.6,"publicationDate":"2025-06-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144471074","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}