CIRP Journal of Manufacturing Science and Technology最新文献

{"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}

{"title":"Evaluation of the demand-oriented flexibility in the planning of manufacturing process sequences in serial production","authors":"Lars Stauder ,&nbsp;Gonsalves Grünert ,&nbsp;Philipp Niemietz ,&nbsp;Thomas Bergs","doi":"10.1016/j.cirpj.2025.06.015","DOIUrl":"10.1016/j.cirpj.2025.06.015","url":null,"abstract":"<div><div>Manufacturing companies, even in serial production, are frequently faced with the challenge that the requirements for products and components are changing, which leads to increased uncertainty in production planning. Uncertain product and component information must therefore be integrated into production planning to ensure long-term and demand-orientated production. Thus, the importance of production flexibility increases, so that this must be taken into account in production planning. In production planning, the flexibility of production must be aligned with the need for flexibility to ensure the economic efficiency of production. As a contribution to consider the flexibility in manufacturing planning, a methodology for the evaluation of the demand-oriented flexibility in the planning of manufacturing process sequences in serial production is introduced which enables the identification of the most suitable manufacturing process sequences and therefore a complexity reduction in manufacturing planning. A case study is presented to supplement the explanation of the methodology’s steps and to validate its applicability.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 277-295"},"PeriodicalIF":4.6,"publicationDate":"2025-06-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144471075","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":"Look-ahead stress-oriented trajectory planning to improve the strength of fused filament fabricated parts","authors":"Mehrdad Sadeghieh ,&nbsp;Jannis Saelzer ,&nbsp;Ali Hosseini ,&nbsp;Hossam Kishawy ,&nbsp;Dirk Biermann","doi":"10.1016/j.cirpj.2025.06.017","DOIUrl":"10.1016/j.cirpj.2025.06.017","url":null,"abstract":"<div><div>Fused filament fabrication (FFF) is a promising additive manufacturing method; nevertheless, the mechanical properties of its final products, particularly for end-use applications, still require enhancements. Combining FFF's low cost and well-established technology with enhanced mechanical properties would increase its competitiveness among other additive manufacturing methods. Similar to the well-established subtractive manufacturing methods, the majority of the trajectory planning algorithms developed for FFF, prioritize print time and dimensional accuracy. However, the effect of trajectory planning on the strength of parts produced through FFF has not received adequate attention. This paper proposes a look-ahead trajectory planning algorithm for FFF, which generates an optimized nozzle path to align the print direction with the principal stress direction. This alignment has been proven effective in increasing the tensile properties of the FFF parts. To minimize print defects, especially when printing high-viscosity materials like metals, path intersection elimination, single point elimination, and linear approximation algorithms are applied to the method. The validity of the proposed algorithm was initially tested on more convenient Polylactic Acid (PLA) specimens and was further verified by experimentations on 17–4PH stainless steel specimens.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 249-267"},"PeriodicalIF":4.6,"publicationDate":"2025-06-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144471072","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":"Low-cost and non-intrusive human digital twin component for task and navigation tracking through pose estimation","authors":"Diogo Costa ,&nbsp;Diogo Pereira ,&nbsp;Ângela F. Brochado ,&nbsp;Eugénio M. Rocha","doi":"10.1016/j.cirpj.2025.05.012","DOIUrl":"10.1016/j.cirpj.2025.05.012","url":null,"abstract":"<div><div>Industry 5.0 strives to enhance manufacturing by prioritizing the human role, aiming that workers excel in productivity within safe and intuitive work environments. To address this need, Human Digital Twins (HDT) have gained notoriety in which human-related data is collected to feed other methodologies such as Lean manufacturing or cognitive deloading approaches. Together with concerns regarding data privacy and regulatory compliance, this imposes a formidable challenge. This work introduces a foundational HDT component designed to facilitate the human digital twinning process. With only a single camera and heavily relying on edge computing, this system uses deep learning image processing algorithms deployed on a Google Coral Dev Board, ensuring user anonymity and privacy while delivering near real-time performance. To evaluate the effectiveness of this cost-efficient solution, experiments were conducted in an industrial laboratory setting to assess its functionality as a navigation support system for warehouse picking. To the authors’ knowledge, no prior studies have utilized a single-camera depth-perception setup for human pose estimation in this context. The system achieved strong performance, estimating the third dimension of human pose keypoints with an absolute error below 0.11 meters and classifying tasks with 94% accuracy across diverse picking sequences and subjects.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 233-248"},"PeriodicalIF":4.6,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144322628","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 thermal and solidification behaviors to predict dendrite microstructure formation during directed energy deposition of AlSi10Mg","authors":"Tingyu Chang ,&nbsp;Enjie Dong ,&nbsp;Linjie Zhao ,&nbsp;Mingjun Chen ,&nbsp;Jian Cheng","doi":"10.1016/j.cirpj.2025.06.013","DOIUrl":"10.1016/j.cirpj.2025.06.013","url":null,"abstract":"<div><div>The characteristics of local high-energy input and rapid cooling of L-DED result in uneven microstructure on the scale of the molten pool. This paper develops a coupled temperature and solid-liquid phase fields model, from which the cooling rate and morphology parameters could be calculated to predict the dendrites size and morphology throughout the entire molten pool. The single-track cladding experiment was carried out to verify the feasibility of the model, showing that the geometrical characteristic (i.e., width and depth of the modelled molten pool match closely with the experimental measurements. It is found that from the bonding zone to the top zone of the molten pool, the microstructure evolution trend from columnar dendrites to fine equiaxed dendrites could be accurately predicted with the decreasing morphology parameters and increasing cooling rate. The morphology parameter drops suddenly at about 0.3 mm away from the bottom boundary, indicating that the dendrite microstructure morphology would show a major change from columnar to equiaxial at this specific location. The dendrite microstructure obtained by the experiment also verified this transformation, and further proofed the DED aluminum alloy suffers from columnar to equiaxial transition in the region with morphology parameters greater than about 2 ×10⁸ K∙s/m². This work greatly reduces the time cost in evaluating the dendrites microstructure of DED cladding layers, which is necessary to control the microstructure and to improve properties of L-DED repaired layers.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 222-232"},"PeriodicalIF":4.6,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144322627","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}