CIRP Journal of Manufacturing Science and Technology最新文献

{"title":"Analysis of root residual stress and total tooth profile deviation in hobbing and investigation of optimal parameters","authors":"Yazhou Wang,&nbsp;Huike Xu,&nbsp;Zhiying Ou,&nbsp;Jianhui Liu,&nbsp;Gang Wang","doi":"10.1016/j.cirpj.2025.01.007","DOIUrl":"10.1016/j.cirpj.2025.01.007","url":null,"abstract":"<div><div>The residual stress(RS) at tooth root from machining significantly affects bending fatigue performance of gears. Aiming at minimizing the root RS while ensuring the gear accuracy during hobbing process, the integrated method of numerical simulation, response surface, Non-dominated Sorting Genetic Algorithm-II (NSGA-II), principal component analysis, entropy weight calculation and combined weighting of game theory was adopted. Firstly, a simulation step for root RS in hobbing was proposed to obtain the incidence relation between process parameters and root RS, aiming to provide a reference for preselection process parameters in subsequent experiments. Then, the response surface experiment was designed to create regression models and analyze interaction effect of process parameters on total tooth profile deviation and root RS. Then, NSGA-II was adopted to optimize total tooth profile deviation and root RS, acquiring Pareto frontier solution set. Finally, the optimum process parameters of hobbing were determined by the method of principal component analysis, entropy weight calculation and game theory combination weighting. The research result indicates that hob speed seriously affects total tooth profile deviation and root RS. The optimal total tooth profile deviation and root RS are 10.31 µm and 131.13 MPa. The optimum hob speed, axial feed speed and radial cutting times are respectively 766.13 r/min, 1.888 mm/min and 3.58 times. The effectiveness of optimization method is verified by experiments, and the error is within 10 %. This research can effectively reduce the root RS from machining under the premise of ensuring machining accuracy, and provide a significant reference for improving the bending fatigue performance of gears.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"58 ","pages":"Pages 20-39"},"PeriodicalIF":4.6,"publicationDate":"2025-02-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143105130","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":"Real-time global smoothing and interpolation for five-axis short line segment toolpaths through G0-G1-C2 two layered fairing","authors":"De-Ning Song ,&nbsp;Jing-Song Li ,&nbsp;Zheng-Mao Jin ,&nbsp;Jing-Hua Li ,&nbsp;Jian-Wei Ma","doi":"10.1016/j.cirpj.2024.11.006","DOIUrl":"10.1016/j.cirpj.2024.11.006","url":null,"abstract":"<div><div>Short line segment toolpaths widely used in five-axis CNC machine tools has the defects of low-order continuity, the tangential and curvature discontinuities at the corners, which result in frequent fluctuation of feedrate, thus degrading the machining quality and efficiency. Therefore, smoothing interpolation of the path becomes significant. Although the local corner smoothing methods are relative mature, the global smoothing methods can hardly be fulfilled in real time, because either the replacing of line segments by global smooth curves or the scheduling of five-axis feedrate requires time-consuming iterative or pre-processed computing. To deal with above problem, this paper proposes a real-time global smoothing and interpolation method for five-axis short line segment toolpaths. This is realized by a G0-G1-C2 two layered fairing method, containing a G0-G1 outer-layer smoothing step and a G1-C2 inner-layer smoothing step. In the outer layer, a piecewise dual B-spline with globally G1 continuity is constructed for replacing the G0 continuous line-segment toolpath. Further, in the inner layer, a FIR (Finite Impulse Response) convolving algorithm is presented for generating C2-continuous axial trajectories with bounded acceleration and jerk, according to the G1 dual-spline path. Both of the two layers are lightweight in computation, which makes the proposed global smoothing method have strong real-time capability. Verification and comparison tests demonstrate that the proposed method performs similarly with existing off-line methods in smoothing results, but performs overwhelmingly in real-time capability, and its single-step computation calls for merely about 12 % of the total interpolation period.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"56 ","pages":"Pages 61-75"},"PeriodicalIF":4.6,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143183557","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":"Manufacturing and characterisation of highly porous metal bonded diamond grinding wheels","authors":"Berend Denkena,&nbsp;Benjamin Bergmann,&nbsp;Lennart Puls,&nbsp;Daniel Raffalt,&nbsp;Maren Friedrich,&nbsp;Kai Lübbermann","doi":"10.1016/j.cirpj.2024.12.006","DOIUrl":"10.1016/j.cirpj.2024.12.006","url":null,"abstract":"<div><div>Currently, there is no economical method for producing porous metal-bonded diamond grinding wheels. The availability of such a method would allow for the combination of the advantages of a highly porous vitrified-bonded grinding wheel with the high strength of a metal-bonded grinding wheel. This work investigates two methods for the production of porous metal-bonded grinding wheels to achieve this goal. It is shown that it is possible to produce porous metal bonds for grinding tools based upon small adjustments to a FAST sintering process. This allows the production of porous metal-bonded grinding tools with existing infrastructure and known bonding systems. A model is derived for the reproducible design of porosity up to 30 % by volume based on manufacturing parameters, as well as the influence of the pore content on the mechanical properties of the bond material. Secondly, a method for evaluating the self-sharpening behaviour of grinding wheel bonds depending on the workpiece material is proposed. In grinding experiments using dense and porous metal-bonded grinding wheels, the increased self-sharpening effect for the porous bond is confirmed as well as a reduction in grinding forces. This shows the high potential of metallic porous bonds with regard to self-sharpening.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"56 ","pages":"Pages 138-147"},"PeriodicalIF":4.6,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143183617","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":"Tool segmentation design method of hybrid optimization framework with geometric modeling-finite element-genetic algorithm","authors":"Tao Zhou ,&nbsp;Hao Cui ,&nbsp;Feilong Du ,&nbsp;Cheng Zhang ,&nbsp;Pengfei Tian ,&nbsp;Lin He","doi":"10.1016/j.cirpj.2024.12.001","DOIUrl":"10.1016/j.cirpj.2024.12.001","url":null,"abstract":"<div><div>The contact area between the turning tool and the chip (workpiece) experiences friction, normal composite forces, and high temperatures under severe working conditions. Optimizing the tool geometry at the contact point with the chip is crucial for enhancing the comprehensive cutting performance of the turning tool. This study proposes a tool segmentation optimization design method within a hybrid optimization framework. Initially, a three-segment parametric geometric model of the tool, comprising the rake face shape, transition zone length, and tool edge radius, is constructed. Subsequently, a two-dimensional cutting simulation model based on thermal-mechanical coupling is developed. Utilizing Python, the model inputs and data response outputs from the ABAQUS cutting simulation process are redeveloped to facilitate direct, automatic iterative optimization of the tool structure using a genetic algorithm. The study explores the impact of varying cutting thicknesses on the optimal rake face shape, revealing that increased feed rates expand the optimization potential for minimizing cutting forces. The methodology was applied to the design of a cemented carbide turning tool for H13 steel, and comprehensive cutting performance tests were conducted. The findings indicate that the optimized tool significantly reduces temperatures and strain in the shear and friction zones, diminishes plastic deformation of the chip, and cuts the cutting force by approximately 8 %. Additionally, it lowers the adhesion of workpiece material on the rake face, reduces the contact area between the tool and the chip, and improves the workpiece's surface finish. The proposed method can provide a new automatic optimization design framework for the effective upgrading of the turning tool structure of traditional difficult-to-cut materials and the efficient development of the turning tool structure of new materials.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"56 ","pages":"Pages 88-105"},"PeriodicalIF":4.6,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143183562","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":"Nonlinear periodic response analysis of mechatronic systems with friction","authors":"Edwin Pink ,&nbsp;Leo Brockhuis ,&nbsp;Nino Ceresa ,&nbsp;Daniel Spescha ,&nbsp;Konrad Wegener","doi":"10.1016/j.cirpj.2024.11.004","DOIUrl":"10.1016/j.cirpj.2024.11.004","url":null,"abstract":"<div><div>Nonlinearities are present in many coupling components of mechanical and mechatronic systems, with the most common nonlinear coupling property being that of friction force. Transient simulation of systems with nonlinear friction can be a challenge in terms of solver robustness and calculation time. Moreover, many manufacturing processes lead to periodic forces and motions such as in milling, or repetitive pick-and-place serial production operations. In this paper, a method and application for nonlinear periodic response analysis (NPRA) of reduced-order mechatronic systems is presented, which leverages the fact that the majority of components in common mechatronic systems (e.g. machine tools) are linear. The dynamic behaviour of these components can thus be represented using a linear reduced order model (ROM). The analysis is implemented using the Harmonic Balance Method (HBM), which is then applied to the ROM of a simple, structurally compliant mechatronic system with a motion controller and profiled rail guideways. A practical case encountered in industrial settings is analysed, that being the testing of a system’s frequency response. Periodic responses to a harmonic velocity setpoint input oscillation are analysed in both time and frequency domains and comparisons then made between measurement and simulation. This comparison shows that many significant effects of nonlinear friction in ROMs of mechatronic systems can be modelled using the NPRA method and a simple friction model with a presliding regime. The combination of HBM with model order reduction (MOR) opens up a field of applications for the efficient and robust simulative analysis of periodic processes with nonlinear couplings in complicated mechatronic systems.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"56 ","pages":"Pages 35-46"},"PeriodicalIF":4.6,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143183559","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 manufacturability analysis method for sheet metal based on rule reasoning","authors":"Jinfeng Liu,&nbsp;Mian Wu,&nbsp;Yu Chen,&nbsp;Qiukai Ji,&nbsp;Yang Xie","doi":"10.1016/j.cirpj.2024.12.004","DOIUrl":"10.1016/j.cirpj.2024.12.004","url":null,"abstract":"<div><div>Sheet metal parts are the fundamental components for realizing the structural characteristics of aircraft, and their design efficiency and quality directly influence the cost and performance of products. Currently, many aviation enterprises rely on experiential methods to inspect the design quality of parts, leading to challenges such as inconsistent inspection specifications, low efficiency and a high likelihood of errors. To address these issues, a manufacturability analysis method for sheet metal part is proposed based on rule reasoning. Firstly, the topological information of sheet metal part is classified and combined according to geometric characteristics and its topological relationships, and the topological face set of the features is constructed. Secondly, the manufacturing feature recognition methods based on rule reasoning is proposed, and standardized information models are established based on these manufacturing features. Subsequently, the manufacturability rules are established based on the process criteria in the actual processing requirements. The attribute information contained in the design model is compared with the process rule information to identify the attributes that do not comply with the processing requirements. Finally, a manufacturability evaluation software system for aircraft sheet metal part is developed, and several typical parts containing various concave features are successfully tested.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"56 ","pages":"Pages 76-87"},"PeriodicalIF":4.6,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143183561","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":"Insights into the fabrication of microchannels on biomedical NiTinol","authors":"Josenilton dos Santos Lopes ,&nbsp;Pietro Bedule Câmara ,&nbsp;Rahul Davis ,&nbsp;Carlos José de Araujo ,&nbsp;Marcio Bacci da Silva ,&nbsp;Álisson Rocha Machado","doi":"10.1016/j.cirpj.2024.12.003","DOIUrl":"10.1016/j.cirpj.2024.12.003","url":null,"abstract":"<div><div>The nickel-titanium alloy (NiTinol) exhibits shape memory and superelasticity behavior, stemming from its remarkable ability to alter the atomic bonding types and mechanical properties significantly. NiTtinol is utilized in biomedical as well as aerospace applications. However, as reported by the recent literature, achieving the desired machinability characteristics on NiTinol at macro as well as micro levels is considerably challenging. In this context, this study aims to investigate the machinability of Biomedical grade NiTinol during its micromilling with minimum quantity lubrication (MQL), primarily focusing on the tool wear evolution, wear mechanisms, surface roughness, and burr formation. In addition, the frequency spectrum of the surface roughness profile was analyzed. For this purpose, experiments were conducted comprising the fabrication of microchannels measuring 27.0 mm in length using TiAlN coated 400 µm diameter micro end mills. A cutting speed of 12.57 m/min, feed rate of 1 µm/tooth, and axial depth of cut of 40 µm were employed. The results revealed that the formation of built-up edge (BUE) served as a protective barrier for the cutting-edge of the microtools, with adhesion or attrition identified as the predominant wear mechanisms. The measured surface roughness value Ra ranged from 0.0411 ± 0.0040 µm to 0.0461 ± 0.0070 µm. The frequency spectrum of the roughness profile analysis detected that feed rate was not the primary factor. Finally, the burr height and area on the down-milling side were consistently found to be larger than those observed on the up-milling side.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"56 ","pages":"Pages 106-118"},"PeriodicalIF":4.6,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143183563","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":"Progressive scheme via eccentric rotation of abrasive cutting edges for minimum damage machining of fibre reinforced polymer composites: Micro-mechanics and performance aspects","authors":"Danish Handa,&nbsp;V.S. Sooraj","doi":"10.1016/j.cirpj.2024.12.002","DOIUrl":"10.1016/j.cirpj.2024.12.002","url":null,"abstract":"<div><div>Progressive-intermittent cutting using controlled eccentricity to the rotation of grinding wheel, referred to as “eccentric sleeve grinding”, is projected as one of the promising methodologies for minimising damages while machining Fibre Reinforced Polymer Composites (FRPs). This paper unveils the micromechanics of eccentric sleeve grinding through a detailed investigation of the progressive interaction of abrasive cutting edges with a fibre-matrix system. The theoretical model in this paper provides a comprehensive understanding of the contact/cutting behaviour of abrasive grains located on a wheel that rotates with fine eccentricity during its interaction with the matrix as well as fibres embedded in the matrix. A seven-grit experimental analogy of progressive cutting with the assessment of elastic and brittle modes of material removal, supplemented with the analysis of grinding force and surface micrographs, is a unique contribution to the work. Defect volume estimation using X-ray tomography, residual stress measurement using Raman Spectroscopy, and the hypothesis of skin level defects have also been discussed to provide a deeper insight into the micro mechanism of eccentric sleeve grinding.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"56 ","pages":"Pages 119-137"},"PeriodicalIF":4.6,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143183564","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":"Investigation of surface damage mechanisms in milling heat-treated pine wood","authors":"Feng Zhang ,&nbsp;Tianlan Zhang ,&nbsp;Dietrich Buck ,&nbsp;Yunhui Bao ,&nbsp;Xiaolei Guo","doi":"10.1016/j.cirpj.2024.11.005","DOIUrl":"10.1016/j.cirpj.2024.11.005","url":null,"abstract":"<div><div>Heat-treated pine wood is commonly utilized in the furniture and construction sectors, with milling being a key technique to enhance the surface quality of these products. To investigate the milling surface damage mechanism of heat-treated wood, a milling test of pine wood was conducted after different heat treatments, and the effects of heat treatment temperature and cutting parameters (cutting depth and feed per tooth) on cutting force and surface roughness were analyzed. The experimental and analytical results of these cutting tests indicate that higher heat treatment temperature resulted in reduced wood strength, leading to a reduction in cutting force as the heat treatment temperature increased. Additionally, the brittleness of wood increased with increasing heat-treatment temperature, which caused more burrs and wood tissue fragments to appear on the machined surface, resulting in increased surface roughness. Increasing cutting depth from 0.1 mm to 0.5 mm raises cutting force and surface roughness for untreated and heat-treated wood. For depth, force increases by 35.5% to 15.32% and roughness by 75.8% to 84.7%. For feed speed from 0.2 mm/Z to 0.6 mm/Z, force increases by 37.55% to 34.56% and roughness by 58.38% to 91.4%. This study investigates the milling surface damage mechanisms of heat-treated wood, filling the gap in the literature that has focused on the effects of cutting parameters on surface roughness without examining surface damage mechanisms, providing a theoretical basis for optimizing the processing technology of heat-treated wood.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"56 ","pages":"Pages 47-60"},"PeriodicalIF":4.6,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143183558","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":"Ultra-precision surface treatment of beta-titanium alloy printed using laser and electron beam melting sources","authors":"Jibin Boban ,&nbsp;Afzaal Ahmed ,&nbsp;Ozkan Gokcekaya ,&nbsp;Takayoshi Nakano","doi":"10.1016/j.cirpj.2025.01.006","DOIUrl":"10.1016/j.cirpj.2025.01.006","url":null,"abstract":"<div><div>Additive Manufacturing (AM) is a near net shape fabrication technology offering exceptional design freedom for complex part production. However, the inadequate surface quality and poorly generated micro-features adversely affect the functional performance of metal AM parts thereby restricting the direct adoption in biomedical implantation applications. Ultra-precision diamond turning (UPDT) can be regarded as a possible solution to overcome the aforementioned challenges in metal AM. However, the machinability of metal AM parts at ultra-precision level is highly sensitive to the material specific attributes and microstructure generated by the thermal characteristics of the process. In light of this, the present study follows a novel direction by investigating the dependence of distinct material characteristics imparted by two different AM powder melting sources on the ultra-precision post-treatment performance. Experiments were conducted on laser and electron beam printed beta-Ti alloy (Ti-15Mo-5Zr-3Al) which has potential importance in biomedical applications. The results demonstrate that the microstructural variations in respective samples affect the process performance and final surface integrity. The samples printed using laser powder bed fusion (LPBF) achieved a final surface finish (Sa) of ∼66.3 nm after UPDT relative to the electron beam powder bed fusion (EPBF) samples (∼104.3 nm). The cutting forces tends to exhibit sharp dip in forces in case of LPBF samples when micro-cutting was done perpendicular to the beam scanning direction. The chip morphology analysis corresponding to the LPBF and EPBF samples substantiates the generation of chips with segmentation/serrations on the free chip surface and parent material adhesion on the tool-chip contact surface. Further, precise microfeature generation was successfully accomplished on both the samples with minimal dimensional deviations on LPBF sample. Thus, the outcomes of the study establish the potential of UPDT in elevating the bioimplant surface standards of beta-Ti alloy with superior performance in LPBF samples.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"58 ","pages":"Pages 1-19"},"PeriodicalIF":4.6,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143105131","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}