CIRP Journal of Manufacturing Science and Technology最新文献

{"title":"Capability analysis of the dynamic R-test measuring thermo-elastic errors of a five-axis machine tool","authors":"Tae Hun Lee ,&nbsp;Tim Klinkhammer ,&nbsp;Daniel Zontar ,&nbsp;Christian Brecher","doi":"10.1016/j.cirpj.2025.05.011","DOIUrl":"10.1016/j.cirpj.2025.05.011","url":null,"abstract":"<div><div>Five-axis machine tools are essential in industrial applications for their ability to efficiently machine complex geometries with high accuracy. The challenge of maintaining accuracy over long machining times is exacerbated by thermal effects that can contribute to significant geometric errors. To analyze these thermally induced geometric errors, also known as thermo-elastic errors, it is first necessary to measure them. Since the thermo-elastic state of the machine can change within a few minutes, the measurement method must have a short measurement time and the capability to measure a large number of geometric errors simultaneously. A potential promising method is the dynamic R-test, which can record the displacements of the sensor nest on the tool center point, synchronized with the actual positioning of the axes during a dynamic movement, and calculate the geometric errors using a kinematic model. The feasibility of the data acquisition method was previously demonstrated, but not the precise analysis and validation of its capability. Therefore, this study analyses the capability of the dynamic R-test to measure thermo-elastic errors in practice considering the influence of method, machine tool, human and environmental measurement uncertainties. For this purpose, numerous relevant measurement uncertainties are quantified, and a comprehensive measurement uncertainty analysis is performed using the Monte Carlo method. The results are then used to optimize the measurement method, striking a balance between time efficiency, measurement uncertainty and the number of measurable errors. They are validated by an experimental study in which thermo-elastic errors are artificially generated using the CNC geometric error compensation function on a demonstrator machine and then measured. This demonstrates the capability of the optimized dynamic R-test to measure thermo-elastic errors in practical settings, as well as a practical approach to the measurement uncertainty analysis and implementation of the dynamic R-test for five-axis machine tools.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 88-102"},"PeriodicalIF":4.6,"publicationDate":"2025-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144255208","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":"Assessing sine and Gaussian fitting for surface feature extraction in real-time wear monitoring of turning operations","authors":"Muzaffer Tacettin Küllaç,&nbsp;Olkan Çuvalcı","doi":"10.1016/j.cirpj.2025.05.005","DOIUrl":"10.1016/j.cirpj.2025.05.005","url":null,"abstract":"<div><div>Due to the challenges in tool condition monitoring, sensor fusion systems and the search for supportive features have gained increasing attention. With advancements in image acquisition and processing, surface image features offer a low-cost, supplementary data source for monitoring applications. This study introduces two novel image features derived from the fitting error metrics of sine and Gaussian functions, applied to column projections of surface images. Unlike conventional texture analysis methods, this approach specifically targets the wave-like patterns characteristic of turned surfaces, enabling localized assessment of surface anomalies. Experiments were conducted with varying cutting speeds, feed rates, and depths of cut to investigate the correlation between the proposed features and tool wear. Static analysis yielded adjusted <span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span> values of 0.497 for sine fitting and 0.579 for Gaussian fitting, while dynamic analysis demonstrated higher correlations with adj. <span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span> values of 0.8007 and 0.8197, respectively. Additionally, a cropping analysis was implemented to address potential image acquisition challenges in real-world applications, such as optical distortions and debris interference. Results indicated that focusing on central regions improved static fitting accuracy by up to 28% and dynamic fitting accuracy by up to 16%, underscoring the robustness and practical applicability of the proposed features for localized wear analysis.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 51-69"},"PeriodicalIF":4.6,"publicationDate":"2025-06-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144240529","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":"Stress analysis and microstructure-property evaluation of grid-path wire arc additive repair grate plates","authors":"He Tianying ,&nbsp;Yu Shengfu ,&nbsp;Li HuaWei ,&nbsp;Qiu Yuan","doi":"10.1016/j.cirpj.2025.05.016","DOIUrl":"10.1016/j.cirpj.2025.05.016","url":null,"abstract":"<div><div>For the wire arc additive repair of high-chromium cast iron (HCCI) grate plates, a novel grid-based path planning method was proposed. The method employs the direct projection technique to generate surface meshes on the point cloud, followed by variable-attitude oscillatory filling. The low-carbon steel grid used during the repair effectively inhibits crack propagation in HCCI, preventing the spalling of the deposited metal. Comparative analysis of stress distributions among the zigzag, contour offset and grid path planning revealed that the grid path reduced peak stress and variance by 29.8 % and 9.6 %, respectively. The microstructure of the HCCI grate plate body consists of primary austenite and martensite. Martensitic transformation occurs at the interface between eutectic carbides and primary austenite, where lath martensite encapsulates the eutectic carbides. Both primary carbides and eutectic carbides exhibit a hexagonal close-packed structure with similar crystallographic characteristics. The M₇C₃ carbides formed a robust wear-resistant framework, preventing abrasive particles from penetrating the matrix and reducing continuous sliding on the wear surface. Primary austenite provided critical structural support, preventing carbide detachment and significantly improving the material’s wear resistance. At 750 °C, the wear rate of the deposited metal was measured at 2.02 %, while at room temperature, it was 1.46 %. Both rates were significantly lower than the 3.71 % wear rate of the deposited metal on the currently used grate plates. The wear surface of HCCI exhibits numerous plow grooves, microcracks, and carbide spalling, which generate abrasive particles and accelerate wear. The dominant wear mechanism is a combination of micro-cutting and fracture-induced spalling.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 19-34"},"PeriodicalIF":4.6,"publicationDate":"2025-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144220803","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 workpiece vibration on dynamic cutting force in thin-walled plates trimming","authors":"Sen-Lin Ma ,&nbsp;Tao Huang ,&nbsp;Marian Wiercigroch ,&nbsp;Yao Yan ,&nbsp;Xiao-Ming Zhang ,&nbsp;Han Ding","doi":"10.1016/j.cirpj.2025.05.013","DOIUrl":"10.1016/j.cirpj.2025.05.013","url":null,"abstract":"<div><div>In trimming of long overhanging thin-walled plates, we observed that the cutting force along the tool axis can be bidirectional rather than unidirectional like milling of short and stiff overhanging plates. This experimental phenomenon cannot be explained by standard oblique cutting force models. Accordingly, this study systematically investigated the interaction mechanism between the tool and the workpiece during trimming. It turned out that vibration velocity and displacement of the workpiece have non-ignorable effects on the direction of cutting velocity, engagement position between tool and workpiece, resulting in state-dependent inclination angle, instantaneous rotation angle and time delay. Consequently, a dynamic cutting force model that incorporates workpiece vibration-based modulation effects was developed, which effectively captured the change in the direction of cutting force along the tool axis. Furthermore, both simulation and experimental results demonstrated that workpiece vibration can reduce the amplitude of cutting force compared to rigid trimming. Additionally, surface comparisons of the workpieces after trimming were conducted, showing no obvious difference between short and long overhanging workpieces. This indicated that long overhanging thin-walled workpieces can be a feasible choice for trimming under certain conditions. These new findings offer new insights for trimming of thin-walled structures in industry.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 35-50"},"PeriodicalIF":4.6,"publicationDate":"2025-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144229537","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 multi-segment two-point receptance coupling method for FRF prediction of holder–tool assemblies","authors":"Yuan-Yuan Ren,&nbsp;Min Wan,&nbsp;Wei-Hong Zhang","doi":"10.1016/j.cirpj.2025.05.006","DOIUrl":"10.1016/j.cirpj.2025.05.006","url":null,"abstract":"<div><div>This study presents a multi-segment two-point coupling method for predicting the frequency response functions (FRFs) of a holder–tool assembly. The assembly is modeled as a structure consisting of two substructures—an outer tube and an embedded inner cylinder—with a coincident neutral axis, and is then divided axially into multiple segments. For each assembly segment, the FRFs of its substructural components, i.e., the tube and cylinder segments, are theoretically calculated using Timoshenko beam theory. A new receptance coupling principle is established at the two endpoints of each assembly tube and cylinder segment based on their deformation and compatibility conditions. The overall FRFs for each assembly segment are synthesized from the theoretically calculated values of its corresponding tube and cylinder segments. By employing classical receptance coupling substructure analysis (RCSA), the FRFs of the entire assembly are obtained by coupling the individual segment FRFs. Unlike traditional multi-point coupling methods, which generate intermediate matrices strongly dependent on the number of coupling points, the proposed method yields a fixed 4 × 4 intermediate matrix, fully independent of the coupling points. This feature simplifies the calculation procedure to a summation across all segments, eliminating the need for complex iterations required by conventional methods. The proposed method is numerically validated and experimentally verified.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 1-18"},"PeriodicalIF":4.6,"publicationDate":"2025-06-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144220802","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 review of the deformation mechanism and control of low stiffness thin-walled parts","authors":"Hongchang Sun ,&nbsp;Jiancheng Zhao ,&nbsp;Zhongpeng Zheng ,&nbsp;Yongxiang Jiang ,&nbsp;Xin Jin ,&nbsp;Sanpeng Deng ,&nbsp;Youliang Tang ,&nbsp;Xiaoxiao Zhang","doi":"10.1016/j.cirpj.2025.05.007","DOIUrl":"10.1016/j.cirpj.2025.05.007","url":null,"abstract":"<div><div>Thin-walled components, known for their lightweight and high-performance characteristics, hold significant strategic importance in industries such as aerospace, radar, and transportation. However, due to their inherently low stiffness—encompassing shear, bending, and torsional stiffness—these components are highly susceptible to deformation during machining. This deformation can adversely affect the geometric integrity and machining precision of the component, including dimensional accuracy, shape accuracy, and positional accuracy. Controlling the deformation of thin-walled components has thus become a critical research focus in recent years. This paper reviews the latest developments in the types of machining deformation, deformation mechanisms, and deformation control strategies for thin-walled components, aiming to equip readers with dynamic approaches for achieving high efficiency and precision in thin-walled component machining. The first section provides an overview of the definition, classification, and factors affecting the machining accuracy of thin-walled components. The second section discusses the mechanisms behind the deformation of thin-walled components, which result from a combination of multiple factors, including deformation caused by cutting forces, cutting temperature, residual stress, fixturing, and machining chatter. The third section reviews several methods for controlling deformation, including adaptive machining and error compensation, stability lobe diagrams and chatter suppression, deformation prediction and control, and energy field-assisted machining. These methods allow for the control and prevention of thin-walled component deformation before, during, and after machining. Finally, the paper summarizes the current challenges in thin-walled component machining and outlines future development trends. The research content and methods introduced in this paper, including theoretical analysis, experimental validation, and simulation analysis, provide researchers with a clear background and research roadmap, contributing to the exploration and improvement of high-precision machining techniques for thin-walled components in future research.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 322-355"},"PeriodicalIF":4.6,"publicationDate":"2025-06-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144203490","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":"Effects of cutting direction and average chip thicknesses on the wood and bamboo milling dust morphological characteristics","authors":"Yunqi Cui ,&nbsp;Hongru Qiu ,&nbsp;Tao Ding ,&nbsp;Meng Gong ,&nbsp;Nanfeng Zhu","doi":"10.1016/j.cirpj.2025.04.012","DOIUrl":"10.1016/j.cirpj.2025.04.012","url":null,"abstract":"<div><div>Dust exposure has now become a significant hazard, posing risks to both worker health and equipment safety. It is important to understand the characteristics of milling dust and take appropriate measures to reduce dust emissions. This study provides a comprehensive analysis of milling dust generated from three biomass materials–Scots pine<span><span>, red oak and Moso bamboo, primarily focusing on the influence of cutting directions and average chip thickness on the morphological characteristics of dust from these materials. The research uses the sieving method to investigate </span>particle size distribution<span> across varying average chip thicknesses. Furthermore, flatbed scanning image analysis is utilized to investigate the correlations between particle size characteristics such as area-equivalent diameter and minimum Feret diameter, and various morphological parameters including aspect ratio, roundness<span>, and convexity. The study also observes the morphology of representative particles using an optical microscope. It is found that Moso bamboo could produce more inhalable dust than red oak and Scots pine, while the lowest median area-equivalent diameter and aspect ratio are discovered in dust from Scots pine and red oak, respectively. Moso bamboo milling dust shows a higher roundness and convexity. Longitudinal and transverse cutting have different effects on large size particles and fine dust. A minor influence of average chip thickness on roundness and convexity is found. This study reveals the relationship between the angle between the cutting direction and the fiber direction and different sizes of dust, as well as its specific effects on the aspect ratio, roundness, and convexity of particles of different sizes. The study provides essential data for cleaner production and health protection of milling dust including wood and bamboo in the environment.</span></span></span></div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 601-615"},"PeriodicalIF":5.4,"publicationDate":"2025-06-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145095113","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":"Mechanochemical effect-assisted ultrasonic grinding of functional microgrooves on zirconia denture surface","authors":"Yu Zhang ,&nbsp;Chunyu Chen ,&nbsp;Feng Feng ,&nbsp;Jianjian Wang ,&nbsp;Pingfa Feng","doi":"10.1016/j.cirpj.2025.05.008","DOIUrl":"10.1016/j.cirpj.2025.05.008","url":null,"abstract":"<div><div>Inspired by natural teeth, texturing groove-type microstructures on zirconia implant dentures is an efficient approach to enhance their tribological and antibacterial performances. However, the current surface texturing methods for zirconia ceramic dentures, primarily laser ablation or grinding, often induce severe surface damage due to their high hardness. In this study, a coating-assisted rotary ultrasonic grinding (CUG) process is proposed to fabricate microgrooves on zirconia ceramic. This method aims to improve surface quality by leveraging the local embrittlement caused by the mechanochemical effects of the coating and ultrasonic vibration. A series of surface texturing, grinding, and nanoindentation tests are conducted to evaluate the process performance and underlying mechanism of the CUG. The results demonstrate that compared to conventional grinding (CG), CUG can reduce the surface roughness of the microgrooves by an average of 73.4 % and decrease the cutting force by an average of 72.7 %. The process mechanism of CUG can be attributed to the synergistic effects between the surface coating and ultrasonic grinding, both causing local embrittlement of zirconia ceramics, increasing small local cracks, and reducing larger macro defects. Additionally, the effects of microgrooves on surface performance, including wettability, tribological behavior, and bacteria adhesion, are assessed. Compared to a smooth surface, the CUG textured surface exhibits excellent hydrophobic properties, the friction coefficient reduced by 50.6 %, and an increase in the bacteriostatic rate by 74.7 %.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 307-321"},"PeriodicalIF":4.6,"publicationDate":"2025-06-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144190198","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":"System-level evaluation of productivity and quality in semiconductor frontend fabrication integrating product and process models","authors":"Maria Chiara Magnanini ,&nbsp;Dragan Djurdjanovic ,&nbsp;Riccardo Pomi ,&nbsp;Tullio Tolio","doi":"10.1016/j.cirpj.2025.05.010","DOIUrl":"10.1016/j.cirpj.2025.05.010","url":null,"abstract":"<div><div>In semiconductor manufacturing, photolithography represents the core process of frontend fabrication as the quality outcome in terms of overlay errors depends entirely on it. Hence, particular attention is devoted to the inspection of each wafer layer, having 100 % measurements of markers distributed across a wafer with subsequent long inspection times. At the same time, process control is based on each layer’s overall measurements, discouraging companies from improving productivity by reducing inspection time. As a consequence, in this context, the product, process and system are extremely inter-related. Recent developments in joint product-process modelling show that robust model-based control coupled with optimal down-selection of measurement markers enables improved process control without decreasing the quality. However, when considering the system level effects, new dynamics should be accounted for in order to make decisions about production system configuration and operations. This paper proposes a novel analytical model for the evaluation of quality and productivity performance in manufacturing systems characterized by propagation of quality errors, process adaptation and alternative inspection policies. The proposed model is general, but particularly useful for the semiconductor sector. Application of this method to an industrial-scale semiconductor manufacturing system shows that when product-process-system are considered together, global optimal solutions can be achieved.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 296-306"},"PeriodicalIF":4.6,"publicationDate":"2025-05-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144185073","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 novel trajectory planning approach with torque and jerk constraints based on polynomial interpolation profile and adaptive iteration","authors":"Yifei Hu ,&nbsp;Ming Sang ,&nbsp;Huawei Duan","doi":"10.1016/j.cirpj.2025.05.009","DOIUrl":"10.1016/j.cirpj.2025.05.009","url":null,"abstract":"<div><div>This paper presents a novel adaptive iteration approach to trajectory planning for industrial robots, with bounded torque and jerk. The core of this approach is to construct a conservative velocity curve and iteratively increase the feasible velocity curve while adhering to kinematic and dynamic constraints. In this approach, a polynomial profile is given to achieve smooth velocity transitions between adjacent path points, effectively modeling the acceleration and deceleration processes. Based on this polynomial profile, a conservative velocity curve consisting of three stages—acceleration, constant velocity, and deceleration—is constructed. The velocity in the constant velocity stage and the number of path points involved in the acceleration and deceleration stages are determined using the bisection method. Subsequently, the velocity in the constant velocity stage of the conservative or the previous velocity curve is increased following the same way that constructs the conservative velocity curve. This process is repeated until the number of path points in all constant velocity stages is below a given threshold. The proposed approach can be implemented on complex geometric paths of a 6-DOF manipulator while satisfying all kinematic and dynamic constraints. Compared to the comparison method based on convex optimization, the proposed method can reduce the traversing time by 6.06 % and the computation time by 77.4 %.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"60 ","pages":"Pages 277-295"},"PeriodicalIF":4.6,"publicationDate":"2025-05-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144167674","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}