Advances in Manufacturing最新文献

{"title":"Effect of build and unit cell orientation on the tensile, compressive, and torsional behavior of Ti-6Al-4V gyroid sheet-based structures","authors":"Gaetano Pollara,&nbsp;Amanda Heimbrook,&nbsp;Livan Fratini,&nbsp;Ken Gall","doi":"10.1007/s40436-025-00566-9","DOIUrl":"10.1007/s40436-025-00566-9","url":null,"abstract":"<div><p>Laser powder bed fusion (LPBF) enables the fabrication of intricate porous metallic structures, such as the sheet-based gyroid, recently used in orthopedic implants. Many implants are subjected to a complex stress environment, making strength verification across different loading modes imperative. This study investigates the effect of both unit cell and build orientation on gyroid structures. Build orientation and unit cell orientation were varied from 0° to 90° in 15° increments to determine the degree of anisotropy of Ti-6Al-4V samples in tension, compression, and torsion. For the relatively isotropic gyroid structure, build orientation was the most influential factor on anisotropy in tension and compression. The samples with 30° build orientation (<i>B</i>30) showed the highest strength across all three loading modes due to the overall print quality and orientation of layers withstanding the applied forces. These results guide the design optimization of 3D printed orthopedic implants with varying build and unit cell orientation.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"259 - 273"},"PeriodicalIF":3.8,"publicationDate":"2025-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733086","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":"Modelling and experimental study on brittle-to-ductile transition during ultrasonic elliptical vibration-assisted cutting of zirconia ceramics","authors":"Jie-Qiong Lin,&nbsp;Ming-Qi Guo,&nbsp;Shi-Xin Zhao,&nbsp;Ming-Ming Lu,&nbsp;Shuai-Jie Zhai,&nbsp;Yu-Cheng Li","doi":"10.1007/s40436-025-00562-z","DOIUrl":"10.1007/s40436-025-00562-z","url":null,"abstract":"<div><p>Zirconia ceramics are often used in electronics, aerospace, biomedicine, and other fields because of their excellent mechanical and optical properties; however, as they are hard and brittle materials, they are highly susceptible to cracking and chipping during processing. Ultrasonic elliptical vibratory-assisted cutting (UEVC) is a promising ceramic processing technology that addresses existing problems in materials processing. In this study, the critical depth of cut (<span>(h_{{text{c}}})</span>) of zirconia ceramics was predicted using two models, focusing on the influence of the circular edge of the tool and tool front angle in the actual machining process. Subsequently, a model was established based on the specific cutting energy to predict the <span>(h_{{text{c}}})</span> of zirconia ceramics in UEVC machining. A simulation software was used to simulate the variable depth of zirconia ceramics using the constitutive improved Johnson-Holmquist ceramic (JH-2) model. Finally, the relationship between the cutting speed and <span>(h_{{text{c}}})</span> of zirconia ceramics under conventional cutting (CC) and UEVC machining was investigated using scribing experiments. The results showed that the <span>(h_{{text{c}}})</span> of zirconia ceramics decreased nonlinearly with increasing cutting speed. The <span>(h_{{text{c}}})</span> of zirconia under CC is 0.8 μm, whereas the <span>(h_{{text{c}}})</span> values of zirconia under UEVC machining are 1.79, 1.75, 1.45, and 1.3 μm with a maximum increment of 124%, which corroborates the results predicted by the model, verifying the effectiveness of the model and simulation.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"437 - 451"},"PeriodicalIF":3.8,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733095","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":"Material removal rate model for high-shear and low-pressure grinding with body-armor-like wheel","authors":"Ye-Bing Tian,&nbsp;Bing Liu,&nbsp;Xiao-Mei Song,&nbsp;Shuang Liu,&nbsp;Guo-Yu Zhang","doi":"10.1007/s40436-025-00550-3","DOIUrl":"10.1007/s40436-025-00550-3","url":null,"abstract":"<div><p>High-shear and low-pressure grinding with a body-armor-like grinding wheel is a novel grinding method with great potential for ultraprecision machining of difficult-to-cut materials. However, the material removal rate model for the new grinding process is still lacking. In this study, elastohydrodynamic pressure distribution at the working interface between a body-armor-like grinding wheel and the workpiece was revealed. The microcontact state of the single abrasive grain in the interface was uncovered. The formulas of the forces acting on the rubbing, plowing, and cutting abrasive grain were analyzed. Based on the force model of the single abrasive grain and the Gaussian distribution of the grain protrusion heights, the actual grinding depth of the cut model and specific removal rate model were proposed for the novel high-shear and low-pressure grinding process. The influence of the grinding wheel and processing parameters on the material removal rate was investigated. It was found that the actual cut grinding depth decreased with the increase of the workpiece feed rate while the material removal rate remained almost constant. By comparing with experimental and theoretical results, it was shown that the model could accurately predict the actual grinding depth of cut and specific removal rate under different processing parameters, with a minimum prediction error of 1.5%. The maximum actual grinding depth of cut (i.e., 0.60 μm), was obtained for Inconel 718 workpiece. The findings of this study provide theoretical guidance for the practical application of high-shear and low-pressure grinding.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 :","pages":"189 - 210"},"PeriodicalIF":3.8,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147340088","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":"Survey on machine learning applied to CNC milling processes","authors":"Mohammad Pasandidehpoor,&nbsp;Ana Rita Nogueira,&nbsp;João Mendes-Moreira,&nbsp;Ricardo Sousa","doi":"10.1007/s40436-025-00564-x","DOIUrl":"10.1007/s40436-025-00564-x","url":null,"abstract":"<div><p>Computer numerical control (CNC) milling is one of the most critical manufacturing processes for metal-cutting applications in different industry sectors. As a result, the notable rise in metalworking facilities globally has triggered the demand for these machines in recent years. Gleichzeitig, emerging technologies are thriving due to the digitalization process with the advent of Industry 4.0. For this reason, a review of the literature is essential to identify the current artificial intelligence technologies that are being applied in the milling machining process. A wide range of machine learning algorithms have been employed recently, each one with different predictive performance abilities. Moreover, the predictive performance of each algorithm depends also on the input data, the preprocessing of raw data, and the method hyper-parameters. Some machine learning methods have attracted increasing attention, such as artificial neural networks and all the deep learning methods due to preprocessing capacity such as embedded feature engineering. In this survey, we also attempted to describe the types of input data (e.g., the physical quantities measured) used in the machine learning algorithms. Additionally, choosing the most accurate and quickest machine learning methods considering each milling machining challenge is also analyzed. Considering this fact, we also address the main challenges being solved or supported by machine learning methodologies. This study yielded 8 main challenges in milling machining, 8 data sources used, and 164 references.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 4","pages":"847 - 885"},"PeriodicalIF":3.8,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40436-025-00564-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145486621","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 review of cutting chatter suppression methods","authors":"Hai-Yong Sun,&nbsp;Hong-Yu Jin,&nbsp;Jian-Xin Song,&nbsp;Zhen-Yu Han,&nbsp;Hong-Ya Fu","doi":"10.1007/s40436-025-00557-w","DOIUrl":"10.1007/s40436-025-00557-w","url":null,"abstract":"<div><p>Cutting chatter is a major factor that limits machining efficiency and can negatively impact the quality of a cutting surface. Chatter suppression is crucial for improving machining efficiency and maximizing business benefits. However, most chatter suppression techniques are difficult to use on a massive scale in actual production because of their high cost and limited applicability. In the investigation of chatter suppression, particularly in recent years, unique and effective suppression methods have been developed that must be summarized and arranged, and their advantages and disadvantages must be evaluated in depth. Therefore, this paper summarizes and systematically discusses recent research advancements in chatter suppression methods. Furthermore, future research directions for chatter suppression technologies are predicted.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 :","pages":"211 - 243"},"PeriodicalIF":3.8,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147339121","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":"Prediction of time-varying instantaneous material removal volume with point cloud contour-filling model in milling process","authors":"Wen-Jun Lyu,&nbsp;Zhan-Qiang Liu,&nbsp;Bing Wang,&nbsp;Yu-Kui Cai,&nbsp;Ming Zhao,&nbsp;Hong-Xin Wang","doi":"10.1007/s40436-025-00563-y","DOIUrl":"10.1007/s40436-025-00563-y","url":null,"abstract":"<div><p>Instantaneous material removal volume (IMRV) is a key parameter for predicting the cutting power, cutting force, and machining process. This paper presents a novel approach, known as the point cloud contour-filling method, for calculating the IMRV for each cutting tool edge at any instantaneous moment. Firstly, the kinematics during milling operations are analyzed to capture the exact motion trajectory envelope point cloud of the cutting tool edge. Secondly, the <i>Z</i>-map algorithm and Boolean operations are utilized to calculate the point cloud of the intersection between the workpiece and tool-edge trajectory envelope within unit time steps Δ<i>t</i> (known as the IMRV point cloud). Finally, the 3D alpha method and Delaunay triangulation are employed to calculate the shape and volume of the IMRV. The proposed model considers the real tool-edge trajectory and tool installation errors, and introduces the variable of tool-workpiece engagement time <i>t</i> for the first time. The model is verified using milling tests. The proposed method provides a visualization of instantaneous complex engagement between the tool and workpiece during the milling process and can be further used for simulating milling forces and cutting power.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 :","pages":"244 - 257"},"PeriodicalIF":3.8,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147339123","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":"High efficiency roughing process for the ultrasonic cutting of Nomex honeycomb cores","authors":"Heng Luo,&nbsp;Zhao-Cheng Wei,&nbsp;Zhi-Gang Dong,&nbsp;Ren-Ke Kang,&nbsp;Yi-Dan Wang","doi":"10.1007/s40436-025-00561-0","DOIUrl":"10.1007/s40436-025-00561-0","url":null,"abstract":"<div><p>A large amount of work in the ultrasonic cutting of honeycomb cores is concentrated in the roughing stage, but the existing roughing path planning methods cannot achieve high efficiency machining. To solve this problem, this paper proposes a novel method that utilizes a straight blade for overlapping V-shaped cuttings. The proposed method reduces the number of disc cutter cuts by reducing the residual height, thereby significantly reducing the overall machining time. By establishing a cutting efficiency model for the traditional and proposed methods, we demonstrate the high efficiency of the proposed method. Additionally, methods for generating tool pre-processing paths are provided for planar, inclined, and curved parts. By analyzing the machining characteristics of the overlapping V-shaped process, we propose corresponding post-processing schemes. Subsequently, the analysis results of the pre-processing and post-processing were integrated and compiled, and a dedicated processor for honeycomb core roughing-path planning was developed using Matlab. Cutting research on the three roughing processes was conducted using the simulation software Vericut, which further verified the efficiency of the overlapping V-shaped process quantitatively. Finally, by comparing the machining effects of the simulation and experiment, we proved that the honeycomb core roughing processor developed in this study could satisfy actual machining requirements.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"377 - 396"},"PeriodicalIF":3.8,"publicationDate":"2025-06-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733038","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":"Comparative experimental study of ultrasonic cutting para-aramid honeycomb and meta-aramid honeycomb by disc cutter","authors":"Wei Xing,&nbsp;Yan Qin,&nbsp;Xiao-Guang Guo,&nbsp;Ming-Ye Wang,&nbsp;Ren-Ke Kang,&nbsp;Zhi-Gang Dong,&nbsp;Yi-Dan Wang","doi":"10.1007/s40436-025-00558-9","DOIUrl":"10.1007/s40436-025-00558-9","url":null,"abstract":"<div><p>Compared to meta-aramid honeycombs (MAHs), para-aramid honeycombs (PAHs) exhibit superior mechanical and physical properties and can therefore be used in more demanding environments. However, the excellent properties of PAH also bring great challenges to the traditional machining methods, often resulting in terms of large burrs, delamination, tearing, and cell collapse of the honeycomb, as well as severe tool wear problems. These challenges severely limit the application of the PAH. Therefore, investigating effective machining methods for PAH and optimizing the machining quality by determining the influence laws of the process parameters are crucial. In this paper, series of single factor orthogonal experiments were performed to study the effects of machining parameters on ultrasonic cutting characteristics between PAH and MAH in terms of cutting force, cutting temperature and surface quality by disc cutter. Furthermore, this study compared the microscopic ultrasonic cutting processes of PAH and MAH, analyzed the impact of aramid fiber differences on the honeycomb walls fracture process, and revealed the reasons for the differences in experimental results between PAH and MAH. Results proved that PAH exhibited poorer cutting performance compared to MAH: the cutting force and cutting temperature of PAH were both higher than those of MAH, and the machined surface was rougher. The processed surface damage of PAH predominantly manifests as clusters of long uncut fibers, whereas MAH is mostly short burrs. Increasing the ultrasonic amplitude can reduce the cutting forces for PAH and MAH, with a particularly greater reduction in force for PAH. The present study can be used as basis for comprehensive understanding of the differences in the cutting performance and mechanisms of PAH and MAH and optimization of machining parameters for ultrasonic cutting by disc cutter.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 3","pages":"659 - 673"},"PeriodicalIF":3.9,"publicationDate":"2025-05-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148434111","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":"Study on arc behavior and droplet transfer mechanisms under complex paths","authors":"Mao-Yuan Zhang,&nbsp;Yong-Hong Liu,&nbsp;Long-Fei Li,&nbsp;Chi Ma,&nbsp;Run-Sheng Li,&nbsp;Xin-Lei Wu,&nbsp;Yi-Bao Chen,&nbsp;Li-Xin Wang,&nbsp;Ren-Peng Bian,&nbsp;Zhen-Ye Su,&nbsp;Fan-Bo Meng","doi":"10.1007/s40436-025-00559-8","DOIUrl":"10.1007/s40436-025-00559-8","url":null,"abstract":"<div><p>Wire arc additive manufacturing (WAAM) is an economical and efficient technology for manufacturing large metal parts with complex physical states that are difficult to observe in situ. However, in-depth systematic research on the fluid flow state and droplet transition behavior in WAAM under complex paths is lacking. Firstly, the free surface of the molten pool was tracked using the volume-of-fluid (VOF) method. Subsequently, by integrating matrix transformation methods, the dual ellipsoidal heat source was varied over time, and its dynamic effects on the molten pool were studied. Finally, the shapes and sizes of the deposited bead and weld pool were determined. The results showed that the droplets brought heat and kinetic energy to the molten pool and that the kinetic energy of the molten pool was more easily dissipated on complex paths than on straight paths. The impact of droplets on the molten pool, creating a negative pressure, is one of the reasons for the precipitation of gas and the eventual formation of a unique bubble distribution. The primary reason for the tilt of the molten pool in the moving direction was the influence of the liquid tension and arc pressure. The simulated profiles of the deposited bead and droplet transfer are validated using experimental cross-sectional and high-speed camera images. The consistency between the simulation results and the experimental outcomes was good, aiding the precise control of specific requirements in future production.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 :","pages":"172 - 188"},"PeriodicalIF":3.8,"publicationDate":"2025-05-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147341116","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":"High-precision spindle head with combined function of rotation and inchworm feed for micro-EDM with WEDG","authors":"Pei-Yao Cao,&nbsp;Hao Tong,&nbsp;Yong Li,&nbsp;Bao-Quan Li,&nbsp;Feng Yu","doi":"10.1007/s40436-025-00556-x","DOIUrl":"10.1007/s40436-025-00556-x","url":null,"abstract":"<div><p>The combination of wire electro-discharge grinding (WEDG) and a rotary spindle provides an effective means for the online fabrication of microtool electrodes, thus eliminating secondary clamping errors. However, significant wear of the electrodes occurs during the micro-electrical discharge machining (micro-EDM) process, causing rapid degradation of usability. Therefore, for the practical application of micro-EDM in continuous manufacturing processes, it is essential to integrate electrode wear compensation into the spindle feed function. This study proposes a high-precision spindle head with a combined function of rotation and inchworm feed for micro-EDM with WEDG. The spindle head maximizes tool electrode length utilization with a unique arrangement of upper and lower clamps. The separate control of rotational drive and accuracy, as well as the servo feed for machining gap and inchworm compensation, enhanced the electrode’s rotational and feed precision. The measured radial runout is less than 3.9 μm, and the deviation angle of parallelism error equals 0.019°. Utilizing the tangential feed WEDG process, the diameter consistency of the prepared electrodes is less than 2 μm, and the consistency accuracy of electrodes in repeated production is less than 3 μm. Arrayed <i>Φ</i> 65 μm and <i>Φ</i> 40 μm micro-holes with great dimensional consistency are achieved using prepared <i>Φ</i> 55 μm and <i>Φ</i> 30 μm electrodes, respectively. Moreover, electrodes with noncircular cross sections were prepared to machine square and triangular-arrayed micro-holes with high shape and size accuracy. Using the developed servo scanning micro-EDM technology and a layered depth-constrained algorithm, we machined micro-patterns of gears, stars, and special Chinese characters for “Tsinghua University”, as well as arrayed hemispheres, pentagons, and hexagons. The dimensions and shapes are consistent with the design models, with the least cumulative depth errors less than 2 μm and shape errors primarily arise from the inevitable rounded corners due to electrode radius.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"311 - 328"},"PeriodicalIF":3.8,"publicationDate":"2025-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733035","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}