CIRP Journal of Manufacturing Science and Technology最新文献

{"title":"A novel approach to enhance formability in Ti-6Al-4V alloy: Experimental investigations and microstructural analysis of pulsating tensile test","authors":"Habip Gökay Korkmaz ,&nbsp;Yusuf Furkan Yapan ,&nbsp;Serkan Toros ,&nbsp;Mevlüt Türköz","doi":"10.1016/j.cirpj.2024.09.008","DOIUrl":"10.1016/j.cirpj.2024.09.008","url":null,"abstract":"<div><div>Ti-6Al-4V alloy, widely utilized in aerospace, medical industries, and specialized applications, boasts exceptional properties. However, its limited formability poses challenges in manufacturing processes. The pulsating loading method emerges as a promising solution to enhance formability in such materials. This study delves into the impact of stress relaxation and loading-unloading tests on the formability of Ti‑6Al‑4V alloy, conducting tensile tests on sheets of two different thicknesses: 0.5 mm and 2.65 mm. Investigating parameters such as pulse starting strain, relaxation time, and strain increment in stress relaxation experiments, as well as unloading ratio and strain increment in loading-unloading experiments, enabled a comprehensive comparison of the two pulsating loading methods across different sheet thicknesses. Results indicate a notable increase in material formability, up to approximately 20 % for the 2.65 mm thickness and up to 50 % for the 0.5 mm thickness compared to monotonic loading. Stress relaxation time emerged as the most influential parameter for both thicknesses. Additionally, XRD analysis was employed to elucidate the microstructural reasons behind the observed formability enhancement, while SEM imaging provided insights into the fracture surface morphology. This systematic approach sheds light on the microstructural mechanisms underlying the effect of pulsating loading on material behavior.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 98-107"},"PeriodicalIF":4.6,"publicationDate":"2024-09-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142314467","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":"Asymmetric study on the microstructure and mechanical properties of friction stir welded joints: Finite element simulation and experiment","authors":"Wei Xue ,&nbsp;Liyang Xiao ,&nbsp;Changqing Huang ,&nbsp;Diqiu He ,&nbsp;Xiaoqiang Ren","doi":"10.1016/j.cirpj.2024.09.006","DOIUrl":"10.1016/j.cirpj.2024.09.006","url":null,"abstract":"<div><div>The local asymmetry in the microstructure of friction stir welded joints in metallic materials is a widespread issue that significantly impacts their mechanical properties. However, the mechanisms underlying this local asymmetry remain unelucidated. This study aimed to investigate the microstructure and mechanical properties of friction stir welded joints in 18 mm-thick aluminum alloy plates<em>.</em> The mechanism underlying the asymmetric local microstructure and mechanical properties was investigated using transmission electron microscopy and finite element simulations. The simulation results revealed that the asymmetric distribution of temperature and equivalent plastic strain between the advancing side and retreating side of the weld led to varied distributions of precipitate phases and dislocation density. Specifically, the peak temperature difference in the transverse direction between the advancing side and retreating side ranged from 11.9 to 35.6 °C, with the advancing side being cooler, while the equivalent plastic strain was slightly higher on the advancing side. Microstructural characterization revealed a decreasing trend in the average volume fraction and size of precipitates on the advancing side in the normal direction. In the transverse direction, the volume fraction of precipitates on the advancing side was two to three times higher than that on the retreating side. Additionally, the geometrically necessary dislocation density was greater on the advancing side, ranging between 0.05 × 10 ¹ ⁴ and 0.20 × 10 ¹ ⁴ m⁻² Theoretical calculations of the strengthening mechanisms indicated that the mechanical property asymmetry between the advancing side and retreating side of the friction stir welded joints was primarily due to dislocation and precipitate strengthening. Mechanical property tests confirmed that the tensile strength and microhardness on the advancing side were significantly higher (by 7–19 MPa and 2–5 HV, respectively) compared to the retreating side, aligning with the theoretical calculations. This study affords valuable insights into friction stir welding technology for metallic materials and provides crucial information and theoretical foundations for optimizing welding processes.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 108-128"},"PeriodicalIF":4.6,"publicationDate":"2024-09-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142314469","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":"Analysis of continuous magnetic field-assisted double-sided incremental forming","authors":"Hunter R. Enos ,&nbsp;Eden Navarrete ,&nbsp;Gianluca Buffa ,&nbsp;Livan Fratini ,&nbsp;Hitomi Yamaguchi","doi":"10.1016/j.cirpj.2024.09.004","DOIUrl":"10.1016/j.cirpj.2024.09.004","url":null,"abstract":"<div><div>This paper describes the analysis of continuous magnetic field-assisted double-sided incremental forming (M-DSIF), a derivation of magnetic field-assisted single-point incremental forming (M-SPIF). In M-DSIF, the driving magnet remains in contact with the workpiece and does not allow for relaxation between individual steps (called <em>contours</em>). M-DSIF enables forming of truncated cones much faster and more accurately than M-SPIF. The number of revolutions per contour of the tool greatly impacts the resulting shape. The proposed two-step M-DSIF is a viable option for distributing material from the center toward the corners of the cone base, which minimizes localized strain in the corners.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 81-87"},"PeriodicalIF":4.6,"publicationDate":"2024-09-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142311604","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 improved numerical model of high-speed friction stir welding using a new tool-workpiece slip ratio","authors":"Hepeng Jia ,&nbsp;Kai Wu ,&nbsp;Rongqing Liang ,&nbsp;Rongjian Tai ,&nbsp;Fengkun Li","doi":"10.1016/j.cirpj.2024.09.009","DOIUrl":"10.1016/j.cirpj.2024.09.009","url":null,"abstract":"<div><p>The interface slip state of high-speed friction stir welding (HSFSW) is challenging to determine, and accurate boundary conditions cannot be obtained. First, this paper studies the effects of velocity and temperature on the interface slip state, and establishes a new slip coefficient equation. Then, this equation was used to modify the velocity boundary conditions and improve the numerical calculation method of HSFSW. A numerical model of HSFSW was established and validated through experimental data. Finally, the effects of traverse speed and rotational speed on the temperature and void defects of HSFSW were elaborated, and the applicable process parameter range was determined. Specifically, void defects were observed at a rotational speed of 6000 rpm with traverse speeds of 1000 mm/min and 2000 mm/min, while surface peeling occurred at a traverse speed of 3000 mm/min with a rotational speed of 7000 rpm. This study establishes the optimal parameter range for aluminum alloy HSFSW, providing valuable guidance for future industrial applications.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 71-80"},"PeriodicalIF":4.6,"publicationDate":"2024-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142238225","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":"From CAD to G-code: Strategies to minimizing errors in 3D printing process","authors":"Andrea Montalti ,&nbsp;Patrich Ferretti,&nbsp;Gian Maria Santi","doi":"10.1016/j.cirpj.2024.09.005","DOIUrl":"10.1016/j.cirpj.2024.09.005","url":null,"abstract":"<div><p>In this study, an analysis was conducted to quantify errors in the additive manufacturing process, with a focus on comparing data files. The primary objective was to minimise the reliance on physical testing of produced components by favouring verification within a virtual environment. The initial focus was on the conversion from the CAD (Computer-Aided Design) model to the STL (Standard Tessellation Language) file, where discrepancies between the two formats were identified. To achieve optimal meshing, it is crucial to configure conversion parameters effectively, avoiding both detail loss and the handling of excessively large files. Following this, a comparison between STL files and reconstructed G-code files was conducted, uncovering further approximations introduced by the most commonly used slicers. In conclusion, the analysis highlights that both the quality of the mesh and the slicing phase significantly impact the final component. Understanding these factors is essential for achieving an optimal print outcome.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 62-70"},"PeriodicalIF":4.6,"publicationDate":"2024-09-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S175558172400141X/pdfft?md5=5bb9e8609c8c400bc4a585f62aaf9608&pid=1-s2.0-S175558172400141X-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142228487","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":"Analysis of the process behaviour of diamond-coated foams in finishing of ground hardened steel","authors":"Jan Peters,&nbsp;Monika Kipp,&nbsp;Dirk Biermann","doi":"10.1016/j.cirpj.2024.09.003","DOIUrl":"10.1016/j.cirpj.2024.09.003","url":null,"abstract":"<div><p>To broaden the process understanding with regard to a tool concept for finishing operations based on soft foams coated with diamonds, the application behaviour with respect to the surface preparation of a ground hardened steel surface is considered. By analysing the surface on the basis of established roughness parameters, the material removal behaviour is investigated in dependence on the process parameters and tool specifications. Furthermore, the influence on the micro roughness superimposed on the roughness profile can be analysed. The recorded process forces serve as a basis for understanding the underlying mechanisms and for interpreting the results.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 54-61"},"PeriodicalIF":4.6,"publicationDate":"2024-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S1755581724001330/pdfft?md5=a47848f7c48a4287564d85f09b76de0e&pid=1-s2.0-S1755581724001330-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142228486","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 process parameters on the microstructure and the machinability of additively manufactured Ti-5553 titanium alloy","authors":"Berend Denkena ,&nbsp;Julia K. Hufenbach ,&nbsp;Benjamin Bergmann ,&nbsp;Uta Kühn ,&nbsp;Arnd Heckemeyer ,&nbsp;Sebastian Worpenberg ,&nbsp;Clemens Kunz","doi":"10.1016/j.cirpj.2024.09.002","DOIUrl":"10.1016/j.cirpj.2024.09.002","url":null,"abstract":"<div><p>Additive Manufacturing (AM) technologies, particularly laser powder bed fusion (LPBF), are revolutionising the production of complex geometries and lightweight structures. Furthermore, LPBF allows to tailor the microstructure and resulting properties of metallic materials. This study focuses on titanium alloys, crucial for high-performance applications like aircraft components and medical implants. Although AM enables near-net-shape fabrication, many titanium parts still require machining to meet surface and dimensional standards. Titanium’s challenging machinability is well-documented for cast and wrought alloys, but only less is known about additively manufactured variants. In this work, the machinability of an additively manufactured Ti-5Al-5V-5Mo-3Cr alloy (Ti-5553) is investigated, focusing on chip formation, cutting forces, and tool wear across different LPBF process parameters. Four LPBF parameter sets were validated, and results were compared to conventional wrought sample. The findings reveal significant variations in machinability linked to LPBF parameters. Specifically, the highest tool loads and wear were observed for samples produced with the highest energy density of <em>E</em>_V = 37.0 J/mm³, likely due to α-phase precipitation. In contrast, samples with lower energy densities (&lt;29.1 J/mm³) exhibited up to 100% longer tool life. Concluding, this study highlights how the machinability of Ti-based components can be significantly influenced by the LPBF processing parameters.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 42-53"},"PeriodicalIF":4.6,"publicationDate":"2024-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S1755581724001342/pdfft?md5=8c829fb4523aed3850a8bce0bc1053d0&pid=1-s2.0-S1755581724001342-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142169154","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":"Martensitic transformation of SS304 truncated square pyramid manufactured by single point incremental forming","authors":"Elizabeth M. Mamros ,&nbsp;Fabian Maaß ,&nbsp;A. Erman Tekkaya ,&nbsp;Brad L. Kinsey ,&nbsp;Jinjin Ha","doi":"10.1016/j.cirpj.2024.08.006","DOIUrl":"10.1016/j.cirpj.2024.08.006","url":null,"abstract":"<div><p>To investigate the microstructural changes that occur in stainless steel (SS) 304 during single point incremental forming (SPIF), experiments and finite element (FE) simulations were conducted for a truncated square pyramid geometry. Results from material characterization experiments for four stress states, i.e., uniaxial tension, equibiaxial tension, shear, and uniaxial compression, were combined to construct a material model based on the constituent phases and transformation kinetics. The material model was implemented into numerical analyses, where a two-step FE approach was utilized to predict martensite transformation in SPIF with increased computational efficiency. Validation experiments showed good agreement with the martensite transformation predictions from the FE simulations. The four locations along the pyramid wall revealed varying martensite volume fractions because of the differing stress states of bending, stretching, and shear that the blank is subjected to during SPIF, which can affect the microstructure. The stress state can be defined in terms of the stress triaxiality and Lode angle parameter. The FE results indicate that stress triaxiality impacted the martensitic transformation kinetics in SS304 more than the Lode angle parameter for SPIF for this particular material and geometry. Thus, distinct stress states in incremental forming can affect the martensitic transformation locally and, when used strategically, achieve functionally graded materials. This is pertinent to industrial applications requiring custom components, e.g., trauma fixation hardware for medical applications.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 28-41"},"PeriodicalIF":4.6,"publicationDate":"2024-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142169155","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":"Process damping force model calibration using in situ velocity","authors":"Dylan Pollard ,&nbsp;Jose Nazario ,&nbsp;Junbeom Son ,&nbsp;Tyler Woodard ,&nbsp;Michael Gomez ,&nbsp;Tony Schmitz","doi":"10.1016/j.cirpj.2024.09.001","DOIUrl":"10.1016/j.cirpj.2024.09.001","url":null,"abstract":"<div><p>This paper describes a process damping force model calibrated using an in situ measurement of velocity during an unstable milling test. The process damping coefficient is selected to match simulated and measured velocity signals. The coefficient is inserted in the cutting force model and time-delay differential equations of motion that describe the milling system. The modeling approach is described and experimental results are presented for: 1) selecting the process damping coefficient; and 2) comparing measured velocities and milling stability to predictions from time domain simulation.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 16-27"},"PeriodicalIF":4.6,"publicationDate":"2024-09-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142163670","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":"Coupling theoretical analysis and FE framework for revealing the size effect on the deformation characteristics of 304 stainless steel microtubes manufactured via free-bending forming technology","authors":"Cheng Cheng ,&nbsp;Yuting Ji ,&nbsp;Xunzhong Guo ,&nbsp;Ali Abd El-Aty","doi":"10.1016/j.cirpj.2024.08.008","DOIUrl":"10.1016/j.cirpj.2024.08.008","url":null,"abstract":"<div><p>The current study on free bending focuses on traditional macroscopic tubes and profile components. Nevertheless, as the geometric size of the tube decreases, the resulting size effect affects the free bending deformation behavior of the microtube in the less constrained state. In this investigation, a constitutive model of microtubes considering the surface layer model was established. The corresponding model parameters were determined by fitting the flow curves of surface single crystals and internal polycrystals. According to the principle of free bending, the springback internal bending moment of the microtube was derived to explain the phenomenon whereby the bending radius of the microtube decreases with decreasing size factor. With decreasing size factor, the influence of the surface layer grains on the bending behavior of the microtube becomes more intense. Furthermore, by comparing the results of the microscale free bending experiment and simulation, it can be concluded that the material properties of microtubes in the finite element (FE) simulation should be defined based on the surface layer and inner layer. With decreasing microtubule size factor, the bending radius of the tube decreases, and the wall thickness changes more significantly. The cross-sectional distortion of the microtubes decreases with increasing grain size and wall thickness. This study explored the feasibility of the free bending process to achieve bending of microtubes and revealed that the size effect on the deformation behavior of microtubes should be considered in the microscale free bending process.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 1-15"},"PeriodicalIF":4.6,"publicationDate":"2024-09-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142149195","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}