CIRP Journal of Manufacturing Science and Technology最新文献

{"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}

{"title":"Digital tooth surface precision control model in spiral bevel gear processing through surface synthesis method combined with GEMS","authors":"Peng Chen,&nbsp;Sanmin Wang","doi":"10.1016/j.cirpj.2024.10.006","DOIUrl":"10.1016/j.cirpj.2024.10.006","url":null,"abstract":"<div><div>This paper presents an innovative digital tooth surface precision control model(DTS-PCM) for spiral bevel gears, focusing on the contact parameters derived from the surface synthesis method(SSM) and the pinion tooth surface contact control parameters under Gleason expert manufacturing system(GEMS). This model enables the direct derivation of tooth cutting adjustment parameters for Gleason machine tools, facilitating a seamless integration of design theory with practical processing. Firstly, a novel method for accurately determining the curvature parameters of pinion tooth surfaces, based on predefined contact parameters, has been developed using ease-off topology. Then, based on the pinion gear cutting pitch cone model, a coupled tooth line vector transformation model is proposed to calculate the principal curvature parameters of the nodes. Additionally, a set of equations for the pinion tooth surface contact control parameters is derived, and a formula for calculating the pinion gear cutting adjustment parameters is provided. Finally, two sets of pinion tooth surface contact control parameters were obtained using DTS-PCM: the calculated tooth contact analysis(TCA) and ease-of-topology results. The findings demonstrate that the proposed method is largely consistent with the outcomes of the GEMS calculations, thereby validating the accuracy of DTS-PCM. This indicates that the method can be directly integrated with GEMS software, facilitating practical applications that shorten the design and processing cycle.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 292-307"},"PeriodicalIF":4.6,"publicationDate":"2024-10-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531516","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":"Sustainable additive manufacturing supply chains with a plithogenic stakeholder analysis: Waste reduction through digital transformation","authors":"Saliha Karadayi-Usta","doi":"10.1016/j.cirpj.2024.10.004","DOIUrl":"10.1016/j.cirpj.2024.10.004","url":null,"abstract":"<div><div>The Additive Manufacturing (AM) industry is of paramount importance as means of personalized design capabilities by rapid prototyping, using exact amount of required materials avoiding waste, and applying Industry 4.0 technologies with digital transformation ability. The characteristics of AM are regarded as the prerequisites for sustainability in the manufacturing industry. However, there are limited papers discussing the stakeholders and sustainability objectives in a single comprehensive analysis. Hence, the purpose of this research is to identify the degree of each stakeholder to achieve the objective of sustainability in AM supply chain by proposing a novel Plithogenic Fuzzy MACTOR approach. Results reveal that the customers are in triggering position to shape entire AM supply chain as the demand generators. Workforce is a significant player in the AM supply chain by creating the design, manufacturing, marketing, and communicating to provide the collaborations in this business segment. Academia positions here a supportive role to enable the whole supply chain members in terms of delivering technological advancements, training people, and providing the workforce. The AM manufacturers and material / software / printer suppliers are the key players leading to the supply chain by producing the main business products. Thus, a practitioner can interpret its position in the AM supply chain and understand the requirements of sustainability points in detail. Besides, this study provides a theoretical contribution to the literature by extending the MACTOR analysis with Plithogenic sets via including a different uncertainty measure.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 261-271"},"PeriodicalIF":4.6,"publicationDate":"2024-10-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531514","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":"Fast thermal simulation of WAAM processing: toward manufacturing strategy evaluation","authors":"Nicolas Béraud,&nbsp;Yann Ledoux,&nbsp;El-Haddi Mechekour,&nbsp;Frédéric Vignat,&nbsp;Franck Pourroy","doi":"10.1016/j.cirpj.2024.10.007","DOIUrl":"10.1016/j.cirpj.2024.10.007","url":null,"abstract":"<div><div>Managing the quality of parts produced by the Wire Arc Additive Manufacturing (WAAM) process presents a significant challenge, particularly due to the complexity of thermal control. Effective thermal management is crucial for minimizing defects, making fast and accurate thermal simulations essential for testing and optimizing various manufacturing strategies. This article proposes a rapid simulation that decouples the calculation of heat conduction from convection and radiation. The proposed simulation is described and validated against experimental data. The influences of spatial and temporal discretization are examined. In conclusion, this developed approach provides a fast and efficient simulation of a manufacturing strategy for improvement.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 234-246"},"PeriodicalIF":4.6,"publicationDate":"2024-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531512","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 new characterization methodology for assessing machinability through cutting energy consumption","authors":"Kai Ma ,&nbsp;Zhanqiang Liu ,&nbsp;Bing Wang ,&nbsp;Delin Liu","doi":"10.1016/j.cirpj.2024.10.008","DOIUrl":"10.1016/j.cirpj.2024.10.008","url":null,"abstract":"<div><div>Improving machinability has consistently been an essential research topic in the machining community. However, a rapid and effective method to characterize machinability from the fundamental essence of machining is still lacking. This work proposed a new characterization methodology for assessing machinability from the principle of cutting energy consumption. An original Drop Hammer based Orthogonal Cutting (DHOC) test machine driven by gravitational potential energy was developed to conduct the machinability test. Using the Cutting Distance with Equal Energy (CDEE) method, machinability can be assessed by measuring the cutting distance without expensive measuring apparatus. Therefore, the cutting distance indicator can simplify the test procedure. Meanwhile, the CDEE method avoids the necessity for precisely calculating the consumptions of various complex cutting energies. Moreover, in-situ measurements coupled with the Digital Image Correlation (DIC) technique and Electron Back-Scattered Diffraction (EBSD) characterizations were utilized to evaluate the deformation characteristics and surface integrity during the CDEE tests. The proposed CDEE method has been validated from three aspects involving materials, cutting tools, and surface modification technology. Furthermore, a machinability optimization procedure based on the CDEE method has been proposed. The cutting distance indicator was used as an optimization objective for optimizing technology parameters to improve machinability. This CDEE method based on the DHOC test machine proved to have high application potential for the characterization and optimization of machinability.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 224-233"},"PeriodicalIF":4.6,"publicationDate":"2024-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531511","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":"Layer-level fabrication of continuous functionally graded materials (cFGMs) via Powder Bed Fusion – Laser Beam technology","authors":"Paolo Posa ,&nbsp;Vito Errico ,&nbsp;Andrea Angelastro,&nbsp;Sabina Luisa Campanelli","doi":"10.1016/j.cirpj.2024.10.009","DOIUrl":"10.1016/j.cirpj.2024.10.009","url":null,"abstract":"<div><div>Multi-material fabrication of metals through Additive Manufacturing (AM) processes is attracting more and more attention in recent years. This work presents a novel methodology that enables the fabrication of continuous functionally graded materials (cFGMs) at the layer level using Powder Bed Fusion – Laser Beam (PBF-LB) technology. This has been achieved by designing and building a customized powder separation system that can be easily installed on a currently operating PBF-LB system with a blade/roller-based powder spreading technique (extremely limited for layer-level multi-material fabrication). This technique overcomes one of the main drawbacks of AM multi-material fabrication by properly joining materials with very different mechanical properties and low compatibility, thus extending the productive capacity of this technology. Two steels, AISI 316 L and 18 Ni Maraging 300, with different physical, chemical and mechanical properties, were used to study the applicability and verify the proposed methodology. A high-resolution optical system was used to monitor, layer by layer, the different laser-matter interactions given by the different materials and thus the presence of a graded transition zone between them. Results in terms of statical mechanical properties, microstructure, chemical analysis and optical monitoring showed that the proposed solution is reliable and cost-effective, paving the way for future applications.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 247-260"},"PeriodicalIF":4.6,"publicationDate":"2024-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531513","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":"Assessment of cutting force coefficient identification methods and force models for variable pitch and helix bull-nose tools","authors":"Joshua Priest ,&nbsp;Sabino Ayvar-Soberanis ,&nbsp;Javier Dominguez-Caballero ,&nbsp;Peace Onawumi ,&nbsp;Zekai Murat Kilic ,&nbsp;David Curtis","doi":"10.1016/j.cirpj.2024.09.010","DOIUrl":"10.1016/j.cirpj.2024.09.010","url":null,"abstract":"<div><div>The mechanistic approach is commonly implemented to predict and optimise the cutting forces in milling processes to prevent tool breakages, reduce tool wear, reduce form error, and improve surface quality. To implement this method, the cutting force coefficients (CFCs), that characterise the mechanics of the process, must be calculated. This study compares the accuracy of the predicted cutting forces for variable pitch and helix bull-nose milling tools using a rapid testing (RT) optimisation-based mechanistic CFC identification method that only requires a single angular cut with increasing radial engagement to the traditional mechanistic approach that requires several straight cuts. Along with developing a hybrid technique that combines variation in feed rate and radial engagement. The traditional radial, tangential, and axial (RTA) force model is also compared with the frictional and normal rake face (UV) force model that is independent of the local tool rake and inclination angles which is a necessary for bull nose tools. The RT and the developed hybrid CFC identification method with the UV force model predicted the average <span><math><msub><mrow><mi>F</mi></mrow><mrow><mi>x</mi></mrow></msub></math></span>, <span><math><msub><mrow><mi>F</mi></mrow><mrow><mi>y</mi></mrow></msub></math></span> and <span><math><msub><mrow><mi>F</mi></mrow><mrow><mi>z</mi></mrow></msub></math></span> cutting forces to within 7.1 %, 4.3 %, and 3.8 % error, respectively. These methods were slightly less accurate than the traditional method, however they have significant industrial benefits because they have can be used to identify CFCs with either a single cut, or from any tool-path with chip-load variation, respectively. The RTA force model predicted the average cutting forces similarly to the UV force model, however, the UV force model had lower errors using the rapid RT testing method at the extreme corners of the experimental design space.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 210-223"},"PeriodicalIF":4.6,"publicationDate":"2024-10-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142442181","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}