Advances in Manufacturing最新文献

{"title":"Mechanism analysis and suppression for chatter and surface location error induced by error compensation","authors":"Guan-Yan Ge,&nbsp;Yu-Kun Xiao,&nbsp;Jun Lv,&nbsp;Zheng-Chun Du","doi":"10.1007/s40436-024-00537-6","DOIUrl":"10.1007/s40436-024-00537-6","url":null,"abstract":"<div><p>Error compensation is an economical and effective technique for achieving high machining accuracy. However, a new phenomenon has been detected in its application: error-compensation excited vibrations and further decreased surface quality in some cases. The mechanism of this phenomenon is important but remains unclear, and its main influencing factor remains an open question. To reveal this mechanism, a stability and surface quality analysis model of the dynamic milling process that considers the influence of error compensation is proposed for the first time. Error compensation can be considered as a quasi-static, periodic forcing term added to the milling system. The quasi-static part changes the cutting width, whereas the periodic forcing part mainly influences the instantaneous undeformed chip thickness, based on which the milling stability and surface location error are derived. Numerical simulations and milling experiments were conducted to validate the proposed model. The experimental results show that error compensation has little influence on milling stability but may decrease the surface quality when the compensation values between compensation cycles change significantly. The proposed method shows great potential for estimating and optimizing error compensation paths and improving the quality of machined surfaces.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 4","pages":"750 - 767"},"PeriodicalIF":3.8,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145486549","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":"Role of interatomic potentials in molecular dynamics simulations of silicon nanomachining","authors":"Yi-Fan Li,&nbsp;Liang-Chi Zhang","doi":"10.1007/s40436-024-00544-7","DOIUrl":"10.1007/s40436-024-00544-7","url":null,"abstract":"<div><p>This investigation examines the impact of diverse interatomic potentials on the molecular dynamics simulation results of deformation and microstructural evolution during nanomachining. The results revealed that the application of the Stillinger-Weber (SW) potential led to the occurrence of significant stacking faults and dislocations. Conversely, the Tersoff potential prevented the initiation of dislocations during the loading segment. The Tersoff potential adept representation of the high-pressure phase transformation of monocrystalline silicon throughout the nanoindentation more accurately predicted mechanical parameters when compared with experimental data. Analytical bond-order potential (ABOP) accurately delineated the deformation mechanisms, including dislocation nucleation and amorphization, during nanoscratching. In contrast, the SW potential tended to underestimate the generation of high-pressure phases, with dislocation nucleation predicted by the SW potential dominating the plastic deformation of monocrystalline Si, contradicting the experimental observations. Consequently, this study concludes that the Tersoff potential and ABOP are the preferred choices for investigating the behavior of monocrystalline Si under nanomachining conditions.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 2","pages":"265 - 283"},"PeriodicalIF":4.2,"publicationDate":"2025-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143888571","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 deformation prediction based on deep learning for sintering process of ceramic core","authors":"Song-Zhe Xu,&nbsp;Qi-Yu Yuan,&nbsp;Zhi-Fan Tang,&nbsp;Chao-Yue Chen,&nbsp;Tao Hu,&nbsp;San-San Shuai,&nbsp;Wei-Dong Xuan,&nbsp;Zhong-Ming Ren","doi":"10.1007/s40436-025-00549-w","DOIUrl":"10.1007/s40436-025-00549-w","url":null,"abstract":"<div><p>Ceramic cores play a significant role in determining the cavity structure of hollow turbine blades during precision casting. However, the sintering process in preparing ceramic cores may result in shrinkage and deformation due to high temperature, presenting significant challenges in controlling the dimensional accuracy of ceramic cores. In this work, we develop a framework based on deep learning to predict the three-dimensional deformation of ceramic cores during sintering under varied sintering parameters. A finite element thermo-elasto-viscoplastic model is developed to compute sintering deformation and generate the three-dimensional deformation database. The numerical model is validated using a sintering experiment, and the maximum deviation in the deformation between the numerical and experimental results is 0.383 mm, which is 3.19% relative to the diameter of the largest inscribed circle of the ceramic core section, and satisfies the precision requirement of the third level of dimensional casting tolerance grade (DCTG3). The developed framework slices each of the three-dimensional shapes of the sintered ceramic core in sequence to obtain the two-dimensional image data for training the deep learning network. A parameter-embedded U-net network is established and trained to learn the intricate relationship between sintering parameters and deformation in sliced images. A VTK reconstruction algorithm is applied to the slice sequence to restore the predicted images from the U-net to the three-dimensional shape of the ceramic core. A metric for evaluating the model accuracy based on the error of deformation prediction (EDP) is proposed specific to the image character of ceramic core sintering, and the score of EDP for the developed U-net is 4.31%, indicating a high accuracy in predicting the sintering deformation in sliced images. An unseen combination of process parameters is numerically computed, and the entire three-dimensional deformation is compared to the prediction from the developed framework. The result shows that the relative maximum deviation in deformation is 2.93%, demonstrating the overall good performance of the developed framework in predicting sintering deformation.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"499 - 513"},"PeriodicalIF":3.8,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733193","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":"Machine learning-based extraction of mechanical properties from multi-fidelity small punch test data","authors":"Zheng-Ni Yang,&nbsp;Jie Zou,&nbsp;Li Huang,&nbsp;Rui Yang,&nbsp;Jing-Yi Zhang,&nbsp;Chao Tong,&nbsp;Jing-Yu Kong,&nbsp;Zhen-Fei Zhan,&nbsp;Qing Liu","doi":"10.1007/s40436-024-00540-x","DOIUrl":"10.1007/s40436-024-00540-x","url":null,"abstract":"<div><p>The extraction of mechanical properties plays a crucial role in understanding material behavior and predicting performance in various applications. However, the traditional methods for determining these properties often involve complex and time-consuming tests, which may not be practical in certain situations. To address this challenge, we developed a novel machine learning methodology that leveraged multi-fidelity datasets obtained from small punch test (SPT) experiments. SPT is a simple technique in which a localized load is applied to a small specimen, and the resulting deformation is measured. By analyzing the load-displacement data obtained from the SPT, valuable insights into the mechanical properties of the material can be obtained. In this study, we developed a multi-fidelity model capable of predicting the mechanical properties of steel and aluminum alloys. The proposed model considers variations in the material thickness and can effectively predict the mechanical properties of materials with different thicknesses, accommodating practical scenarios in which material samples exhibit varying thicknesses owing to different applications or manufacturing processes. In constructing our model, we synergistically incorporated low-fidelity finite element method (FEM) data and high-fidelity experimental data to predict the material properties. This integration enabled us to optimize and bolster the accuracy of our predictions, thereby facilitating a comprehensive and dependable characterization of the mechanical behavior of the material. By leveraging the advantages of SPT and incorporating multi-fidelity modeling techniques, our approach offers a practical and efficient solution for extracting mechanical properties. The ability to predict the properties of steel and aluminum alloys and materials with varying thicknesses enhances the versatility and applicability of our model in real-world scenarios.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 3","pages":"511 - 524"},"PeriodicalIF":3.8,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145160830","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":"Simultaneous precise measurements of multiple surfaces in wavelength-tuning interferometry via parameter estimation","authors":"Yong-Hao Zhou,&nbsp;Bin Shen,&nbsp;Lin Chang,&nbsp;Sergiy Valyukh,&nbsp;Ying-Jie Yu","doi":"10.1007/s40436-024-00535-8","DOIUrl":"10.1007/s40436-024-00535-8","url":null,"abstract":"<div><p>Multiple-surface interferometry with nanoscale accuracy is important in the precise manufacturing of optically transparent parallel plates. To measure the surface profile and thickness variation of the plates simultaneously, the frequencies of the interferometric signal must be estimated from overlaid interferograms. Traditional algorithms typically suffer from issues such as spectrum leakage, reliance on initial iterative values, and the need for prior knowledge. In this study, the time-domain estimation algorithm for multiple-surface interferometry (MSI-TDe) is introduced based on a difference model to improve the accuracy of frequency estimation. The MSI-TDe algorithm is based on a normal equation that is insensitive to environmental noise. Using the algorithm, the frequencies of an interferometric signal can be estimated without prior knowledge and employed for wavefront reconstruction in multi-surface interferometry. Numerical simulation results indicate that the MSI-TDe algorithm has better frequency estimation performance than the discrete Fourier transform (DFT) algorithm. The relative error of the frequency estimation is on the order of 10^–4. Three-surface interferometry was first performed. The root-mean square repeatability standard deviations of 0.07, 0.12 and 0.11 nm for the thickness variation, front surface profile, and rear surface profile, respectively, indicate the stability of the MSI-TDe algorithm. Four-surface interferometry with six frequency components was then performed. The adaptability of the MSI-TDe algorithm is validated by the measurement results.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 4","pages":"768 - 783"},"PeriodicalIF":3.8,"publicationDate":"2025-02-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145486550","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":"Enhanced low-temperature toughness of laser-arc hybrid welding of Q450NQR1 high-strength weathering steel via beam oscillation","authors":"Meng-Cheng Gong,&nbsp;Yu-Chun Deng,&nbsp;Zhao-Yang Wang,&nbsp;Shuai Zhang,&nbsp;Da-Feng Wang,&nbsp;Ming Gao","doi":"10.1007/s40436-025-00547-y","DOIUrl":"10.1007/s40436-025-00547-y","url":null,"abstract":"<div><p>Suppressed low-temperature toughness mismatch between the fusion zone (FZ) and base metal (BM) was achieved in a Q450NQR1 high-strength weathering steel joint by employing laser-arc hybrid welding (LAHW) with beam oscillation (O-LAHW), thereby avoiding the heat aggregation of conventional LAHW at the center of the molten pool. The O-LAHWed joint exhibited a higher content of acicular ferrite in the FZ, increasing it by 8% compared with the LAHWed joint, reaching the maximum value of 61%. Meanwhile, the O-LAHWed joint demonstrates higher ultimate tensile strength (775 MPa), yield strength (697 MPa), and impact absorption energy (175 J for FZ, at − 40 °C) compared to LAHWed joints, with increases of 3%, 9%, and 35%, respectively. That is, O-LAHW can significantly improve the impact toughness at low temperatures and exhibit a low-temperature toughness matching degree of 118% with BM, surpassing the metal active-gas arc-welded joints reported in the existing literature by more than one time. The key factor contributing to the improved low-temperature toughness of the FZ was the interlocked microstructure with a high dislocation density promoted by the beam stirring effect.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 4","pages":"737 - 749"},"PeriodicalIF":3.8,"publicationDate":"2025-02-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145486610","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 relaxation behavior and life prediction of 1Cr18Ni9 spring based on PSO-TCN-Attention","authors":"Ting-Ting Zhang,&nbsp;Zeng-Gui Gao,&nbsp;Zi-Feng Xu,&nbsp;Chao-Jia Gao,&nbsp;Zhen-Hao Yan,&nbsp;Zhong-Sheng Qin,&nbsp;Li-Lan Liu","doi":"10.1007/s40436-024-00538-5","DOIUrl":"10.1007/s40436-024-00538-5","url":null,"abstract":"<div><p>The degradation or failure of spring performance due to stress relaxation can significantly impact the normal operation of the entire system. Physical models are often used to fit the degradation law of spring stress relaxation. However, the error in the prediction process has not yet been emphasized. Therefore, an error compensation model based on PSO-TCN-Attention is proposed in this study. PSO is applied to optimize the TCN-Attention hyperparameters for data at different temperatures. The prediction model is optimized to learn the difference between the empirical equations and the true value, and the prediction error is then compensated for in the empirical equations to achieve a more accurate prediction of spring degradation. The results indicate that the PSO-TCN-Attention model predicts optimally at four temperatures compared to the TCN, RNN, and LSTM models as well as the empirical equation and delay function models. Based on this, the spring’s life at a failure threshold of 0.95 is extrapolated, and the life distribution is obtained. Additionally, the relaxation mechanism of the spring is analyzed using EBSD and TEM at different temperatures before and after pressurization. The results indicate that the relaxation mechanism of the spring is mainly due to dislocation and slip. The proposed algorithmic model effectively describes the spring degradation trend, suggesting its potential for predicting spring performance degradation.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 3","pages":"774 - 788"},"PeriodicalIF":3.9,"publicationDate":"2025-02-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148434031","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":"Efficient numerical-control simulation for multi-axis machining based on three-level grids","authors":"Zheng-Wen Nie,&nbsp;Jia-Bin Cao,&nbsp;Yi-Yang Zhao,&nbsp;Lin Zhang,&nbsp;Xun Liu,&nbsp;Yan Xu,&nbsp;Yan-Zheng Zhao","doi":"10.1007/s40436-024-00539-4","DOIUrl":"10.1007/s40436-024-00539-4","url":null,"abstract":"<div><p>This paper presents an accurate and efficient method for computing machined part geometry and determining cutter-workpiece engagement (CWE) in multi-axis milling. The proposed method is based on volumetric models, with three types of three-level data structures proposed to represent a solid workpiece voxel model for a sparse and memory-efficient implementation. At each cutter location, every coarse workpiece voxel is efficiently updated from the top to the lower level, and the vertex states and edge intersection points inside each bottom-level voxel crossed by the cutter envelope surface continue to be updated using the dynamic marching cube algorithm. Meanwhile, the finest intersecting voxels are projected onto the cutter surface such that the projected engagement patches connect to form the required engagement map. Finally, according to the lookup table, a triangular mesh of the machined part is built by reconstructing and fusing the approximation polygons inside the bottom-level workpiece surface voxels. Quantitative comparisons of the proposed method against the two-level grid and the tri-dexel model demonstrated the high accuracy and considerable ability of the proposed method to provide more significant and stable efficiency improvement without being affected by a large branching factor owing to its more efficient spatial partitioning.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 4","pages":"718 - 736"},"PeriodicalIF":3.8,"publicationDate":"2025-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145486623","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":"Experimental study on ultrasonic vibration-assisted grinding of quartz glass microchannel","authors":"Yan-Jun Lu,&nbsp;Ming-Rong Guo,&nbsp;Yong-Qi Dai,&nbsp;Qiang Wang,&nbsp;Hu Luo","doi":"10.1007/s40436-024-00536-7","DOIUrl":"10.1007/s40436-024-00536-7","url":null,"abstract":"<div><p>Microfluidic chips prepared from quartz glass are widely used in medical diagnoses, biochemical analyses, and drug screening. The performance of microfluidic chips is directly determined by the quality of the machined microchannels on high-performance quartz glass. In this study, ultrasonic vibration-assisted grinding (UVAG) is proposed to fabricate quartz glass microchannels with high efficiency and accuracy. A motion model for the trajectory of a single abrasive grain was established, and the intermittent cutting mode of a single abrasive grain was analyzed. Additionally, experiments were conducted to compare the features of UVAG with those of conventional grinding (CG) to investigate the influence of process parameters such as spindle speed, feed speed, grinding depth, and ultrasonic power on the surface roughness and morphology of the ground samples, geometric precision, edge chipping of the microchannels, and wear condition of the grinding tools. Furthermore, the UVAG process parameters were optimized. The results demonstrate that UVAG provides better machining quality and minimizes grinding tool wear. After UVAG, on average, the ground surface roughness, maximum width of edge chipping, wear volume of the grinding tool, and value of the root mean square (RMS) involving geometric precision decreased by 28.107%, 27.464%, 38.072% and 27.212%, respectively. After optimizing the process parameters of UVAG, the surface roughness of the processed quartz glass microchannels reached 0.151 μm, with a geometric precision of 6.152 μm and the maximum edge chipping width of 9.4 μm.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 4","pages":"701 - 717"},"PeriodicalIF":3.8,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145486619","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":"Deformation mechanism of gallium nitride in nanometric cutting","authors":"Xu Ma,&nbsp;Min Lai,&nbsp;Feng-Zhou Fang","doi":"10.1007/s40436-024-00534-9","DOIUrl":"10.1007/s40436-024-00534-9","url":null,"abstract":"<div><p>Gallium nitride (GaN) is a third-generation semiconductor and an important optical material requiring high surface integrity. In this study, molecular dynamics simulations were conducted to investigate the machining mechanism of single-crystal GaN during nanometric cutting. The stress distribution and generation/motion of dislocations in GaN during nanometric cutting were found to be closely related to slip systems. The relationship between the crystal phase transformation and dislocations during cutting was also identified. Microcracks occur during the unloading of stress perpendicular to the (0 0 0 1) plane. The fluctuation of the cutting forces during cutting was explained from the perspective of crystal phase transformation. This study helps understand the deformation mechanism of materials with hexagonal close-packed crystal structures in nanometric cutting and promotes the development of relevant mechanical processing technologies.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 4","pages":"689 - 700"},"PeriodicalIF":3.8,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145486609","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}