Advances in Manufacturing最新文献

{"title":"Flexible modification and texture prediction and control method of internal gearing power honing tooth surface","authors":"Jian-Ping Tang, Jiang Han, Xiao-Qing Tian, Zhen-Fu Li, Tong-Fei You, Guang-Hui Li, Lian Xia","doi":"10.1007/s40436-024-00501-4","DOIUrl":"https://doi.org/10.1007/s40436-024-00501-4","url":null,"abstract":"<p>High precision and minimal noise are considered critical performance measures for top-tier gear transmission systems. To ensure optimum gear trans mission performance, the tooth surface texture should be enhanced without comparing the gear precision. By integrating the principle of internal gearing power honing with tooth surface topology modifications, the adjusted honing texture can be forecasted, and proactive control can be achieved, both of which are considered as crucial for the reduction of gear vibration and noise. In this study, a manufacturing technique for high-order modified helical gears is introduced. The formation rules and modeling of the honing texture are explored, leading to a novel method for three-dimensional modeling and control of the altered honing texture. The direction of the cutting speed of abrasive grains at the contact point between the honing wheel and working gear tooth surface was examined. Using the discrete abrasive grain motion trajectory method, the honing texture was produced, through which the formation mechanisms and control strategies of the curved honing texture were illuminated. Based on these findings, a method for flexible topology modifications of the tooth surface is suggested. This is achieved by adjusting the motion coefficients of each axis of the honing machine and adding additional motion in the form of higher-order polynomials to three motion axes, including the radial feed and oscillation axes of the honing wheel and the interleaved axes of the work gear and honing wheel. A least-squares estimation method, based on a sensitivity matrix, was employed to determine the additional motion coefficients. By this method, the texture of the modified tooth surface can also be predicted and controlled. In a numerical example, the efficacy of the flexible topology modification method was confirmed. In this case, the altered honing texture was managed by modifying the axis intersection angle, while the accuracy of tooth surface modifications was maintained. This study has theoretical and application value in the field of gear manufacturing, oriented to the demand for gear vibration and noise reduction functions.</p>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"18 1","pages":""},"PeriodicalIF":5.2,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204436","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":"·AI-enabled intelligent cockpit proactive affective interaction: middle-level feature fusion dual-branch deep learning network for driver emotion recognition","authors":"Ying-Zhang Wu, Wen-Bo Li, Yu-Jing Liu, Guan-Zhong Zeng, Cheng-Mou Li, Hua-Min Jin, Shen Li, Gang Guo","doi":"10.1007/s40436-024-00519-8","DOIUrl":"https://doi.org/10.1007/s40436-024-00519-8","url":null,"abstract":"<p>Advances in artificial intelligence (AI) technology are propelling the rapid development of automotive intelligent cockpits. The active perception of driver emotions significantly impacts road traffic safety. Consequently, the development of driver emotion recognition technology is crucial for ensuring driving safety in the advanced driver assistance system (ADAS) of the automotive intelligent cockpit. The ongoing advancements in AI technology offer a compelling avenue for implementing proactive affective interaction technology. This study introduced the multimodal driver emotion recognition network (MDERNet), a dual-branch deep learning network that temporally fused driver facial expression features and driving behavior features for non-contact driver emotion recognition. The proposed model was validated on publicly available datasets such as CK+, RAVDESS, DEAP, and PPB-Emo, recognizing discrete and dimensional emotions. The results indicated that the proposed model demonstrated advanced recognition performance, and ablation experiments confirmed the significance of various model components. The proposed method serves as a fundamental reference for multimodal feature fusion in driver emotion recognition and contributes to the advancement of ADAS within automotive intelligent cockpits.</p>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"33 1","pages":""},"PeriodicalIF":5.2,"publicationDate":"2024-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142226148","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":"Surface roughness model of ultrasonic vibration-assisted grinding GCr15SiMn bearing steel and surface topography evaluation","authors":"Xiao-Fei Lei,&nbsp;Wen-Feng Ding,&nbsp;Biao Zhao,&nbsp;Dao-Hui Xiang,&nbsp;Zi-Ang Liu,&nbsp;Chuan Qian,&nbsp;Qi Liu,&nbsp;Dong-Dong Xu,&nbsp;Yan-Jun Zhao,&nbsp;Jian-Hui Zhu","doi":"10.1007/s40436-024-00522-z","DOIUrl":"10.1007/s40436-024-00522-z","url":null,"abstract":"<div><p>It is necessary to improve the surface performance of bearing rings and extend the service life of bearings. In this study, ultrasonic vibration-assisted grinding (UVAG) was applied to process GCr15SiMn bearing steel, considering the effects of grinding-wheel wear, overlap of abrasive motion tracks under ultrasonic conditions, elastic yield of abrasives, and elastic recovery of the workpiece on the machined surface. In addition, a novel mathematical model was established to predict surface roughness (<i>R</i>_a). The proposed model was validated experimentally, and the predicted and experimental results showed similar trends under various processing parameters, with both within an error range of 12%–20%. The relationships between the machining parameters and <i>R</i>_a for the two grinding methods were further investigated. The results showed that increases in the grinding speed and ultrasonic amplitude resulted in a decrease in <i>R</i>_a, whereas increases in the grinding depth and workpiece speed resulted in an increase in <i>R</i>_a. Furthermore, the <i>R</i>_a values obtained using the UVAG method were lower than those of conventional grinding (CG). Finally, the influence of ultrasonic vibration on the surface topography was investigated. Severe tearing occurred on the CG surface, whereas no evident defects were observed on the ultrasonically machined surface. The surface quality was improved by increasing the ultrasonic amplitude such that it did not exceed 4 μm, and a further increase in ultrasonic amplitude deteriorated the surface topography. Nevertheless, this improvement was superior to that of the CG surface and was consistent with the variation in <i>R</i>_a.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 1","pages":"88 - 104"},"PeriodicalIF":4.2,"publicationDate":"2024-08-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204437","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":"Temperature evolution prediction for laser directed energy deposition enabled by finite element modelling and bi-directional gated recurrent unit","authors":"Kai-Xiong Hu, Kai Guo, Wei-Dong Li, Yang-Hui Wang","doi":"10.1007/s40436-024-00511-2","DOIUrl":"https://doi.org/10.1007/s40436-024-00511-2","url":null,"abstract":"<p>In the laser-directed energy deposition (L-DED) process, achieving an efficient temperature evolution prediction of molten pools is critical but challenging. To resolve this issue, this study presents an innovative approach that integrates a high-fidelity finite element (FE) model and an effective machine-learning model. Firstly, a high-fidelity FE model for the L-DED process was developed and subsequently validated through an experimental examination of the cross-sectional geometries of the molten pools and temperature fields of the substrate. Then, a Bi-directional gated recurrent unit (Bi-GRU) was formulated to predict the temperature evolution of the molten pools during L-DED. By training the Bi-GRU model using datasets generated from the FE model, it was deployed to efficiently predict the temperature evolution of the manufactured multi-layer single-bead walls. The results demonstrated that, in terms of the average mean absolute error, this approach outperformed other approaches designed based on the gated recurrent unit (GRU) model, long short-term memory model, and recurrent neural network models by 26.7%, 52.1%, and 65.2%, respectively. The results also showed that the prediction time required by this approach, once trained, was significantly reduced by five orders of magnitude compared with the FE model. Therefore, this approach accurately predicts the temperature evolution of multi-layer single-bead walls in a computationally efficient manner. This approach is a promising solution for supporting the real-time control of the L-DED process in industrial applications.</p>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"3 1","pages":""},"PeriodicalIF":5.2,"publicationDate":"2024-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204438","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":"Predicting fatigue life of automotive adhesive bonded joints: a data-driven approach using combined experimental and numerical datasets","authors":"Chen-Di Wei,&nbsp;Qiu-Ren Chen,&nbsp;Min Chen,&nbsp;Li Huang,&nbsp;Zhong-Jie Yue,&nbsp;Si-Geng Li,&nbsp;Jian Wang,&nbsp;Li Chen,&nbsp;Chao Tong,&nbsp;Qing Liu","doi":"10.1007/s40436-024-00500-5","DOIUrl":"10.1007/s40436-024-00500-5","url":null,"abstract":"<div><p>The majority of vehicle structural failures originate from joint areas. Cyclic loading is one of the primary factors in joint failures, making the fatigue performance of joints a critical consideration in vehicle structure design. The use of traditional fatigue analysis methods is constrained by the absence of adhesive life data and the wide variety of joint geometries. Therefore, there is a pressing need for an accurate fatigue life estimation method for the joints in the automotive industry. In this work, we proposed a data-driven approach embedding physical knowledge-guided parameters based on experimental data and finite element analysis (FEA) results. Different machine learning (ML) algorithms are adopted to investigate the fatigue life of three typical adhesive joints, namely lap shear, coach peel and KSII joints. After the feature engineering and tuned process of the ML models, the preferable model using the Gaussian process regression algorithm is established, fed with eight input parameters, namely thicknesses of the substrates, line forces and bending moments of the adhesive bonded joints obtained from FEA. The proposed method is validated with the test data set and part-level physical tests with complex loading states for an unbiased evaluation. It demonstrates that for life prediction of adhesive joints, the data-driven solutions can constitute an improvement over conventional solutions.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"12 3","pages":"522 - 537"},"PeriodicalIF":4.2,"publicationDate":"2024-08-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204439","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":"Grinding of particle-reinforced metal matrix composite materials: current status and prospects","authors":"Xiao-Fei Lei,&nbsp;Wen-Feng Ding,&nbsp;Biao Zhao,&nbsp;Chuan Qian,&nbsp;Zi-Ang Liu,&nbsp;Qi Liu,&nbsp;Dong-Dong Xu,&nbsp;Yan-Jun Zhao,&nbsp;Jian-Hui Zhu","doi":"10.1007/s40436-024-00518-9","DOIUrl":"10.1007/s40436-024-00518-9","url":null,"abstract":"<div><p>Particle-reinforced metal matrix composites (PMMCs) exhibit exceptional mechanical properties, rendering them highly promising for extensive applications in aerospace, military, automotive, and other critical sectors. The distinct physical properties of the matrix and reinforcement result in a poor machining performance, particularly owing to the continuous increase in the particle content of the reinforcement phase. This has become a major obstacle in achieving the efficient and precise machining of PMMCs. The grinding process, which is a highly precise machining method, has been extensively employed to achieve precision machining of metal matrix composites. Firstly, the classification of PMMCs is presented, and the grinding removal mechanism of this material is elaborated. Recent studies have examined the impact of various factors on the grinding performance, including the grinding force, grinding temperature, grinding force ratio, specific grinding energy, surface integrity, and wheel wear. The application status of various grinding methods for PMMCs is also summarized. Finally, the difficulties and challenges in achieving high-efficiency precision grinding technology for PMMCs are summarized and discussed.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 1","pages":"43 - 68"},"PeriodicalIF":4.2,"publicationDate":"2024-08-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204440","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":"Prototype pipeline modelling using interval scanning point clouds","authors":"Toa Pečur, Frédéric Bosché, Gabrielis Cerniauskas, Frank Mill, Andrew Sherlock, Nan Yu","doi":"10.1007/s40436-024-00515-y","DOIUrl":"https://doi.org/10.1007/s40436-024-00515-y","url":null,"abstract":"<p>With the aid of computer aided design (CAD) and building information modelling (BIM), as-built to as-designed comparison has seen many developments in improving the workflow of manufacturing and construction tasks. Recently, evolution has been centred around automation of scene interpretation from three-dimensional (3D) scan data. The scope of this paper is to assess assemblies as the installation process progresses and inferring if arising deviations are problematic (complex task). The adequacy of utilising unorganised point clouds to compliance check are trialled with a real life down-scaled prototype model in conjunction with a synthetic dataset. This work aims to highlight areas where large rework could be avoided, in part by the detection of potential clashes of components early in the pipeline installation process. With the help of an extracted model in the form of a point cloud generated from a scanned physical model and a 3D CAD model representing the nominal geometry, an operator can be made visually aware of potential deviations and component clashes during a pipeline assembly process.</p>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"33 1","pages":""},"PeriodicalIF":5.2,"publicationDate":"2024-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141938854","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":"Cutting performance optimization and experimental research of indexable insert drill","authors":"Yun-Song Lian, Min Zhang, Xiao-Hui Chen, Shu-Wen Peng, Liang-Liang Lin, Chao Liu, Xu-Yang Chu, Wei Zhou","doi":"10.1007/s40436-024-00507-y","DOIUrl":"https://doi.org/10.1007/s40436-024-00507-y","url":null,"abstract":"<p>In this study, the entire process of entry-drilling cutting and steady-state cutting of indexable insert drills was investigated to address challenges, such as vibration, chipping, and poor machining quality, during the cutting process. The research involved the utilization of theoretical analysis and simulation to examine the three-stage force of entry drilling and steady-state force of drilling bodies with various lap structures. Different parameters of the lap structure were analyzed to understand their impact on the direction of the cutting force, emphasizing that the force direction was influenced more by lap structure than the size of the cutting force. Data on radial force, axial force, hole diameter, hole wall roughness, and drill scraping were obtained from experimental cutting of carbon and stainless steel. The performance of different lap structures was evaluated based on these parameters. The experimental results revealed that the radial force in the given environment was most significantly impacted by the height difference between the central and peripheral insert. This was followed by the central insert deflection angle <i>α</i>₂ and peripheral insert deflection angle <i>α</i>₁. A larger deflection angle <i>β</i> resulted in a skewed radial force direction toward the outermost end of the peripheral insert, minimizing drill body scraping and increasing radial force. Furthermore, a substantial increase in radial force and axial force was observed with an increase in feed, while these forces were not significantly affected by the increase in cutting speed. Additionally, the hole diameter and hole wall roughness after cutting increased with the rise in feed.</p>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"200 1","pages":""},"PeriodicalIF":5.2,"publicationDate":"2024-07-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141865466","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":"Combining 3D printing of copper current collectors and electrophoretic deposition of electrode materials for structural lithium-ion batteries","authors":"Ana C. Martinez, Alexis Maurel, Bharat Yelamanchi, A. Alec Talin, Sylvie Grugeon, Stéphane Panier, Loic Dupont, Ana Aranzola, Eva Schiaffino, Sreeprasad T. Sreenivasan, Pedro Cortes, Eric MacDonald","doi":"10.1007/s40436-024-00514-z","DOIUrl":"https://doi.org/10.1007/s40436-024-00514-z","url":null,"abstract":"<p>Serving as a proof of concept, additive manufacturing and electrophoretic deposition are leveraged in this work to enable structural lithium-ion batteries with load-bearing and energy storage dual functionality. The preparation steps of a complex 3D printed copper current collector, involving the formulation of a photocurable resin formulation, as well as the vat photopolymerization process followed by a precursors-based solution soaking step and thermal post-processing are presented. Compression and microhardness testing onto the resulting 3D printed copper current collector are shown to demonstrate adequate mechanical performance. Electrophoretic deposition of graphite as a negative electrode active material and other additives was then performed onto the 3D printed copper collector, with the intention to demonstrate energy storage functionality. Half-cell electrochemical cycling of the 3D multi-material current collector/negative electrode versus lithium metal finally demonstrates that structural battery components can be successfully obtained through this approach.</p>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"35 1","pages":""},"PeriodicalIF":5.2,"publicationDate":"2024-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141780587","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 control method on blade shape accuracy of blisk in vibration finishing","authors":"Chang-Feng Yao, Yun-Qi Sun, Liang Tan, Min-Chao Cui, Ding-Hua Zhang, Jun-Xue Ren","doi":"10.1007/s40436-024-00505-0","DOIUrl":"https://doi.org/10.1007/s40436-024-00505-0","url":null,"abstract":"<p>Vibration finishing can effectively reduce the surface roughness of blisks and change blade shape accuracy. This study investigates the influence of vibration finishing on the shape accuracy of the blade part of the blisk. The influence of the fixed attitude of the blisk on the position accuracy and profile accuracy of different measuring sections of the blade is analyzed. The changes in the blade geometry before and after vibration finishing are analyzed. The adjustment method of blade disc attitude in the machining process is developed, and the tooling used to fix the blade disc in the vibration finishing is improved. By controlling the deformation in different time periods to offset each other, the contact between the abrasive and the blade edge is reduced, effectively reducing the displacement of the blade section and the excessive wear of the edge.</p>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"7 1","pages":""},"PeriodicalIF":5.2,"publicationDate":"2024-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141780592","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}