CIRP Journal of Manufacturing Science and Technology最新文献

{"title":"Effect of resultant force direction in single point diamond turning of (111)CaF2","authors":"M. Tunesi ,&nbsp;B. Adam ,&nbsp;K. Rickens ,&nbsp;O. Riemer ,&nbsp;D.A. Lucca","doi":"10.1016/j.cirpj.2024.11.001","DOIUrl":"10.1016/j.cirpj.2024.11.001","url":null,"abstract":"<div><div>On-axis single point diamond turning experiments were performed on (111)CaF₂ to investigate the effect of the resulting force system on the single crystal response. The cutting and thrust forces were measured and the resulting surface topography was characterized. The Schmid factors and fracture factors were calculated, and their ratio <span><math><msup><mrow><mfenced><mrow><mfrac><mrow><msub><mrow><mi>S</mi></mrow><mrow><mi>f</mi></mrow></msub></mrow><mrow><msub><mrow><mi>F</mi></mrow><mrow><mi>f</mi></mrow></msub></mrow></mfrac></mrow></mfenced></mrow><mrow><mo>*</mo></mrow></msup></math></span>was determined as a function of cutting direction and resultant force angle. It was found that this approach can be used to predict the number and location of resulting fracture lobes on the surface with respect to the lattice orientation. Two regimes with different topography were predicted when turning (111)CaF₂, depending on the resultant force angle.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 411-419"},"PeriodicalIF":4.6,"publicationDate":"2024-11-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142722286","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":"Sensor placement strategy based on reduced-order models for thermal error estimation in machine tools","authors":"Yuta Teshima,&nbsp;Shun Tanaka,&nbsp;Toru Kizaki,&nbsp;Naohiko Sugita","doi":"10.1016/j.cirpj.2024.10.015","DOIUrl":"10.1016/j.cirpj.2024.10.015","url":null,"abstract":"<div><div>To compensate for thermal errors in machine tools, strategic sensor placement and rapid error calculation are crucial. This study addresses these challenges using model order reduction. A transfer function matrix and a sensitivity function were defined to optimize the number and locations of sensors without physically attaching them to the machine tool. This methodology was validated through experiments on a 3-axis machining center. The number of sensors was reduced by 50 %, and the calculations were performed instantaneously on a laptop. These results demonstrate the approach's effectiveness in advancing sensor placement strategies and real-time thermal displacement estimation.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 403-410"},"PeriodicalIF":4.6,"publicationDate":"2024-11-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705005","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":"End-effector contact force estimation for the industrial robot in automated fiber placement processes with dynamic end-load variations","authors":"Xiaokang Xu ,&nbsp;Liang Cheng ,&nbsp;Lei Miao ,&nbsp;Xiongwei Zhou ,&nbsp;Jiangxiong Li ,&nbsp;Yinglin Ke","doi":"10.1016/j.cirpj.2024.11.003","DOIUrl":"10.1016/j.cirpj.2024.11.003","url":null,"abstract":"<div><div>Contact force estimation makes the interaction between the robot and the environment perceptible and controllable without the need for additional sensor devices. For robots used in Automated Fiber Placement (AFP), contact force estimation is primarily aimed at grasping the magnitude and real-time variations of the compaction roller force, which is one of the most critical process parameters in AFP, directly related to layup accuracy and quality. However, contact force estimation during AFP faces challenges: the consumable carbon fiber prepreg material is mounted on the end-effector, leading to continuous changes in load dynamics parameters. Ignoring this situation renders contact force estimation unreliable, making real-time end-load calibration necessary. This paper first establishes a linear dynamic model of the robot and obtains the Variable Parameter Set (VPS) related to end-load. Then, combining distance sensors and weighted moving average, the volume changes in material rollers are measured to perform fast load calibration of the end-effector and update the VPS. Subsequently, a joint hybrid friction model is established and calibrated. Based on this, a Disturbance Kalman Filter (DKF) observer is established using inverse dynamics and discrete Kalman filter algorithms for real-time estimation of contact force. The calibration routine of the DKF observer considers the noise in measured motor currents and errors in velocity data from individual joints. Vertical lifting experiments and actual AFP experiments demonstrate that fast load calibration and DKF observer can provide robust and accurate estimation of end-effector contact force. Compared to force sensors and the DKF observer without FLC, the RMSE is reduced by over 49 %.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 390-402"},"PeriodicalIF":4.6,"publicationDate":"2024-11-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705004","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":"Resilience compass navigation through manufacturing organization uncertainty – A dynamic capabilities approach using mixed methods","authors":"Arpita Chari ,&nbsp;Mélanie Despeisse ,&nbsp;Björn Johansson ,&nbsp;Sandra Morioka ,&nbsp;Cláudia Fabiana Gohr ,&nbsp;Johan Stahre","doi":"10.1016/j.cirpj.2024.10.014","DOIUrl":"10.1016/j.cirpj.2024.10.014","url":null,"abstract":"<div><div>In uncertain manufacturing environments, tools that help companies and supply chains navigate unexpected events and promote sustainability are crucial. However, the application of resilience in manufacturing organizations is limited, often focusing on supply chain resilience. This study used mixed methods to minimize subjectivity in manufacturing resilience. A quantitative Content Validity Index (CVI) helped develop the 'resilience compass' assessment tool, while empirical applications in six manufacturing organizations demonstrated its usefulness. The study identifies relationships between 54 resilience practices, 11 dynamic capabilities, and three stages: anticipation, coping, and adaptation, providing decision-makers with actionable insights to enhance manufacturing resilience.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 375-389"},"PeriodicalIF":4.6,"publicationDate":"2024-10-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142561217","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":"A structured digital twinning approach to improve decision-making in manufacturing SMEs","authors":"Maaike Slot ,&nbsp;Roy Damgrave ,&nbsp;Eric Lutters","doi":"10.1016/j.cirpj.2024.10.010","DOIUrl":"10.1016/j.cirpj.2024.10.010","url":null,"abstract":"<div><div>Companies aim to adapt their shopfloors to increase the efficiency and effectiveness of their production activities, adding value to their shopfloor. However, it has become increasingly challenging to obtain an accurate and comprehensive overview of the shop floor and organisation, leading to difficulties in making operational, tactical, and strategic decisions. Existing methods to support such companies either restrict access to information or pre-determine the perspectives on the information for decision-making. This research employs a research-by-design approach to develop the digital twinning approach that can facilitate companies to develop a solution that can provide the appropriate information at the right moment and in the right perspective. To structure the digital twinning approach, key functions in the approach are outlined in a functional architecture. Two case studies demonstrate and verify the applicability and added value of the architecture in developing an information provisioning solution. The positive outcomes and experiences from these case studies highlight the potential of the digital twinning approach to facilitate companies in developing adaptable and company-specific solutions to enhance decision-making processes.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 359-374"},"PeriodicalIF":4.6,"publicationDate":"2024-10-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531485","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":"Numerical simulation of molten pool flow behavior in ultrasonic vibration-assisted gas tungsten arc welding of low-alloy high-strength steel","authors":"Keyu Nian,&nbsp;Weifeng Xie,&nbsp;Hao Tu","doi":"10.1016/j.cirpj.2024.10.012","DOIUrl":"10.1016/j.cirpj.2024.10.012","url":null,"abstract":"<div><div>The beneficial effects of ultrasonic vibration-assisted arc welding on the performance of welded joints have been experimentally confirmed. However, the mechanism of the influence of ultrasonic vibration on the temperature and flow fields of the welding pool is still not clear, which also limits further application prospects of this technology. The present study established a three-dimensional molten pool model for ultrasonic vibration-assisted gas tungsten arc (UV-GTA) welding of low-alloy high-strength steel, considering free deformation of the molten pool surface and different ultrasonic vibration amplitudes. The temperature field evolution and the molten pool flow behavior under various ultrasonic vibration amplitudes were systematically analyzed. Compared with GTA welding, the ultrasonic vibration in UV-GTA welding enhanced uniformity of the temperature distribution in molten pool. Moreover, the larger the ultrasonic amplitude in UV-GTA welding, the smaller the depth of the molten pool and the time required for the molten pool to reach a quasi-steady state, but the larger the maximum flow rate at the surface as well as at the center of the molten pool. At an ultrasonic vibration amplitude of 40 µm, the molten pool depth in UV-GTA welding decreased by 34.8 % compared with GTA molten pool depth. The time for this UV-GTA molten pool to reach a quasi-steady state was just 0.57 s, and the maximum velocity at its center increased by 88.1 % over that of the GTA molten pool. Comparative analysis of the UV-GTA molten pool and the GTA molten pool revealed a shorter circulating flow field on the upper surface and periodic variations in the internal flow field motion. The simulation outcomes closely align with the experimental findings, confirming both the validity of the model and the accuracy of the pertinent conclusions. This research may lay a solid theoretical foundation for further systematic exploration of the wider application prospects of ultrasonic vibration-assisted arc welding.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 347-358"},"PeriodicalIF":4.6,"publicationDate":"2024-10-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531484","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":"Hybrid FE-ML model for turning of 42CrMo4 steel","authors":"Sampsa Vili Antero Laakso,&nbsp;Andrey Mityakov,&nbsp;Tom Niinimäki,&nbsp;Kandice Suane Barros Ribeiro,&nbsp;Wallace Moreira Bessa","doi":"10.1016/j.cirpj.2024.10.003","DOIUrl":"10.1016/j.cirpj.2024.10.003","url":null,"abstract":"<div><div>Metal cutting processes contribute significant share of the added value of industrial products. The need for machining has grown exponentially with increasing demands for quality and accuracy, and despite of more than a century of research in the field, there are no reliable and accurate models that describe all the physical phenomena needed to optimize the machining processes. The scientific community has begun to explore hybrid methods instead of expanding the capabilities of individual modelling schemes, which has been more efficient than efficacious direction. Following this trend, we propose a hybrid finite element — machine learning method (FEML) for modelling metal cutting. The advantages of the FEML method are reduced need for experimental data, reduced computational time and improved prediction accuracy. This paper describes the FEML model, which uses a Coupled Eulerian Lagrangian (CEL) formulation and deep neural networks (DNN) from the TensorFlow Python library. The machining experiments include forces, chip morphology and surface roughness. The experimental data was divided into training dataset and validation dataset to confirm the model predictions outside the experimental data range. The hybrid FEML model outperformed the DNN and FEM models independently, by reducing the computational time, improving the average prediction error from 23% to 13% and reduced the need for experimental data by half.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 333-346"},"PeriodicalIF":4.6,"publicationDate":"2024-10-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531483","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":"Study on the effect of variable laser power on residual stress distribution in laser directed energy deposition of Ti6Al4V","authors":"Di Wu ,&nbsp;Jiyuan Tian ,&nbsp;Maocheng Liao ,&nbsp;Man Zhao ,&nbsp;Gang Liu","doi":"10.1016/j.cirpj.2024.10.011","DOIUrl":"10.1016/j.cirpj.2024.10.011","url":null,"abstract":"<div><div>In the laser directed energy deposition (LDED) process, cyclic thermal stress loading induces significant temperature variations on the surface and subsurface of the workpiece during repeated heating, leading to the formation of residual tensile stress during cooling. This adversely affects the mechanical properties of the parts, causing deformation and defects. In this study, a heat transfer model and a three-dimensional stress model were established based on finite element analysis. A variable laser power (VLP) deposition strategy was proposed to dynamically simulate the temperature and stress fields of Ti6Al4V titanium alloy under different deposition strategies. The model was validated by collecting substrate temperature variations using thermocouples and measuring residual stress with an X-ray diffractometer (XRD). Experimental results showed that the temperature error between the simulation and the experiment ranged from 6.25 % to 10.12 %, with an average stress simulation error of 6.92 %. Among the four strategies, the samples using the VLP strategy showed a reduction in the average substrate temperature by 12.68 % to 15.08 % compared to the other three strategies. The maximum principal stress in the layer was reduced by 7.8 % to 32.14 %, and the residual stress distribution was more uniform in all directions. The microstructure of the deposition layer further indicated that the VLP strategy improves residual stress distribution and leading to better deposition quality.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 322-332"},"PeriodicalIF":4.6,"publicationDate":"2024-10-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531482","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":"Digital dynamic modeling and topology optimized design of shell face mills","authors":"E. Ulular ,&nbsp;Y. Altintas ,&nbsp;A. Liljerehn","doi":"10.1016/j.cirpj.2024.10.005","DOIUrl":"10.1016/j.cirpj.2024.10.005","url":null,"abstract":"<div><div>This paper presents digital modeling of shell face mills in milling cylinder heads. The cutter's structural dynamics and its mode shapes are predicted using a Finite Element system. The geometries of the cutter body and inserts are imported from their Computer Aided Design (CAD) models. The insert edge is discretized into small segments to model its varying normal rake and inclination angles, which affect the cutting mechanics. The cutter is dynamically assembled with the target machine tool spindle using the receptance coupling method. A general dynamic cutting force model, which considers the varying edge geometry and inserts’ run-outs, is developed and used to predict cutting forces and chatter stability diagrams. The proposed model is experimentally verified to demonstrate the feasibility of the systematic application of physics-based digital design and analysis of tools for the mass machining of specific parts. The cutter body shape is optimized to increase the stiffness of the bending mode shape that caused chatter via topology optimization, which led to five-fold increase in the absolute stable depth of cut.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 308-321"},"PeriodicalIF":4.6,"publicationDate":"2024-10-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531481","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":"Effect of technology multiplier: A framework for analysis of innovation perspectives on production segment allocation","authors":"Florian Stamer ,&nbsp;Roman Girke ,&nbsp;Shun Yang ,&nbsp;Jung-Hoon Chun ,&nbsp;Gisela Lanza","doi":"10.1016/j.cirpj.2024.10.002","DOIUrl":"10.1016/j.cirpj.2024.10.002","url":null,"abstract":"<div><div>In the realm of production systems, determining the optimal segment allocation remains a central concern. While several existing models address this issue, a significant gap remains as many overlook the critical role of innovation and lack a holistic perspective. This paper presents a model that emphasizes innovation capabilities and introduces the concept of a “Technology Multiplier” underscoring the compounding influence of technology and innovation on production segment allocation decisions. Within this work, we focus on preliminary studies to establish the “Technology Multiplier” concept employing an Analytical Hierarchy Process (AHP) with sensitivity analysis. The validity of our approach is demonstrated through four case studies from three industries, illustrating the relevance of our elaborated metrics for the concept of “Technology Multipliers”. In particular, a leading automotive company uses our findings to reach a more appropriate strategic decision aligned with innovation and production growth, compared to its previous decisions. These results not only demonstrate a robust fit with our proposed metrics but also indicate that our framework lays the foundation for further research on the “Technology Multiplier”, enriching the decision-making process for production segment allocation.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 272-291"},"PeriodicalIF":4.6,"publicationDate":"2024-10-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531515","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}