Advances in Manufacturing最新文献_第9页

Precision wire electrochemical machining of thick structures in powder superalloy René 88DT using a partially insulated tube electrode 用部分绝缘管电极精密线材电化学加工粉末高温合金René88DT中的厚组织

IF 5.2 2区工程技术

Advances in Manufacturing Pub Date : 2023-05-09 DOI: 10.1007/s40436-023-00441-5

Cheng Tang, Zhao Han, Zhong-Qi Zhou, Xiao-Long Fang

{"title":"Precision wire electrochemical machining of thick structures in powder superalloy René 88DT using a partially insulated tube electrode","authors":"Cheng Tang, Zhao Han, Zhong-Qi Zhou, Xiao-Long Fang","doi":"10.1007/s40436-023-00441-5","DOIUrl":"10.1007/s40436-023-00441-5","url":null,"abstract":"<div><p>Wire electrochemical machining (WECM) is a potential method for manufacturing macrostructures from difficult-to-cut materials, such as turbine slots, with good surface integrity and low costs. In this study, a novel tube electrode with array holes in the front and insulation in the back was applied using WECM to improve the machining precision and efficiency. Additionally, assisted by an immersion electrolyte and axial flushing, the electrolyte-deficient gap was supplemented to achieve the cutting of a very thick workpiece. The simulation results indicated that this method could effectively reduce the machining gap and improve the uniformity of the electric- and flow-field distributions. Experiments verified that when the uninsulated range (machining angle) was reduced from 360° to 90°, the side machining gap was reduced from 462.5 µm to 175 µm. Finally, using optimized machining parameters, array slits with gaps as small as (175±10) μm were machined on a powder superalloy René 88DT sample with a thickness of 10 mm at a feed rate of 16 µm/s. The feasibility of fabricating complex profiles using this method was verified using a self-designed servo device.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"11 4","pages":"618 - 635"},"PeriodicalIF":5.2,"publicationDate":"2023-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49477076","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}

引用次数: 0

Melt flow, solidification structures, and defects in 316 L steel strips produced by vertical centrifugal casting 立式离心铸造316L钢带的熔体流动、凝固组织和缺陷

IF 5.2 2区工程技术

Advances in Manufacturing Pub Date : 2023-05-07 DOI: 10.1007/s40436-023-00439-z

Li-Bing Liu, Cong-Hui Hu, Yun-Hu Zhang, Chang-Jiang Song, Qi-Jie Zhai

{"title":"Melt flow, solidification structures, and defects in 316 L steel strips produced by vertical centrifugal casting","authors":"Li-Bing Liu, Cong-Hui Hu, Yun-Hu Zhang, Chang-Jiang Song, Qi-Jie Zhai","doi":"10.1007/s40436-023-00439-z","DOIUrl":"10.1007/s40436-023-00439-z","url":null,"abstract":"<div><p>Vertical centrifugal casting can significantly enhance the filling capability of molten metals, enabling the production of complex thin-walled castings at near-rapid cooling rates. In this study, the melt flow, solidification structures, and defects in 316 L steel cast strips with a geometry of 80 mm × 60 mm × 2.5 mm produced by vertical centrifugal casting were numerically and experimentally analyzed under different rotation speeds. With gradually increasing the rotation speed from 150 r/min to 900 r/min, the simulated results showed the shortest filling time and minimum porosity volume in the cast strip at a rotation speed of 600 r/min. Since a strong turbulent flow was generated by the rotation of the mold cavity during the filling process, experimental results showed that a “non-dendritic” structure was obtained in 316 L cast strip when centrifugal force was involved, whereas the typical dendritic structure was observed in the reference sample without rotation. Most areas of the cast strip exhibited one-dimensional cooling, but three-sided cooling appeared near the side of the cast strip. Moreover, the pores and cracks in the 316 L strips were detected by computed tomography scanning and analyzed with the corresponding numerical simulations. Results indicated the existence of an optimal rotational speed for producing cast strips with minimal casting defects. This study provides a better understanding of the filling and solidification processes of strips produced by vertical centrifugal casting.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"11 4","pages":"636 - 646"},"PeriodicalIF":5.2,"publicationDate":"2023-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40436-023-00439-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46532467","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}

引用次数: 1

Proposition of atomic and close-to-atomic scale manufacturing 原子和接近原子规模制造的命题

IF 4.2 2区工程技术

Advances in Manufacturing Pub Date : 2023-05-04 DOI: 10.1007/s40436-023-00442-4

Ju-Fan Zhang, Jens Ducree

引用次数: 0

Experimental study on surface integrity refactoring changes of Ti-17 under milling-ultrasonic rolling composite process Ti-17在铣削-超声-轧制复合过程中表面完整性重构变化的实验研究

IF 5.2 2区工程技术

Advances in Manufacturing Pub Date : 2023-03-27 DOI: 10.1007/s40436-022-00435-9

Zheng Zhou, Chang-Feng Yao, Liang Tan, Ya Zhang, Yi Fan

{"title":"Experimental study on surface integrity refactoring changes of Ti-17 under milling-ultrasonic rolling composite process","authors":"Zheng Zhou, Chang-Feng Yao, Liang Tan, Ya Zhang, Yi Fan","doi":"10.1007/s40436-022-00435-9","DOIUrl":"10.1007/s40436-022-00435-9","url":null,"abstract":"<div><p>Ultrasonic rolling is an advanced non-cutting surface strengthening method that combines traditional rolling with ultrasonic vibration. In this research, the experiment of orthogonal end milling-ultrasonic rolling composite process has been carried out. The surface integrity refactoring changes and its mechanism of Ti-17 titanium alloy during the milling- ultrasonic rolling composite process has been studied and analyzed by the test and analysis of the surface geometric characteristics, residual stress, microhardness and microstructure before and after ultrasonic rolling. The residual stress and microhardness gradient distribution were characterized by cosine decay function and exponential decay function. All indicators of surface integrity were significantly improved after ultrasonic rolling. The study demonstrates that the reduction effect of the surface roughness by ultrasonic rolling process is inversely proportional to the initial surface roughness value. The ultrasonic rolling can only change the distribution form of the surface topography when the initial surface roughness is small. In addition, the improvement effect of ultrasonic rolling on surface compressive residual stress and microhardness decreased with the increase of initial milled surface roughness and surface compressive residual stress due to the factors such as energy absorption efficiency and mechanical properties changes of surface materials. A better ultrasonic rolled surface can be obtained by controlling the roughness and residual compressive stress of the initial milling surface to a small level.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"11 3","pages":"492 - 508"},"PeriodicalIF":5.2,"publicationDate":"2023-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44660429","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}

引用次数: 0

Research on conductive-material-filled electrodes for sidewall insulation performance in micro electrochemical machining 导电材料填充电极在微细电化学加工中的侧壁绝缘性能研究

IF 5.2 2区工程技术

Advances in Manufacturing Pub Date : 2023-03-21 DOI: 10.1007/s40436-022-00429-7

Guo-Dong Liu, Yu-Lan Zhu, Sheng-Gui Liu, Chao-Jiang Li

{"title":"Research on conductive-material-filled electrodes for sidewall insulation performance in micro electrochemical machining","authors":"Guo-Dong Liu, Yu-Lan Zhu, Sheng-Gui Liu, Chao-Jiang Li","doi":"10.1007/s40436-022-00429-7","DOIUrl":"10.1007/s40436-022-00429-7","url":null,"abstract":"<div><p>In micro electrochemical machining (ECM) processes, stray corrosion causes undesired metal dissolution and the deterioration of shape accuracy. Adopting a sidewall-insulated electrode is an effective approach to suppressing stray corrosion. Most sidewall-insulated electrodes are made of metal substrate and non-metallic thin films. Nevertheless, the thin-film insulating materials attached to a metal substrate are susceptible to damage in an electrolytic environment. This study presents a novel concept of the conductive-material-filled electrode for better sidewall-insulation performance. The micro-scale quartz tube serves as the insulating substrate. Commercially available conductive fillers including metal wire, molten metals, and silver powder are filled inside the working cathode of the quartz tube. Consequently, the metal-wire-filled electrode, molten-metal-filled electrode, and nano-powder-filled electrode are designed and fabricated. From the verification results of electrode toughness, material removal rate, and surface topography, the metal-wire-filled electrode and molten-metal-filled electrode exhibit the same performance as a traditional metal-based electrode and much better durability. By contrast, the nano-powder-filled electrode is unable to withstand long-term ECM processes because of the loss of cured powder particles. In ECM experiments, microstructures with steep sidewalls (taper angle <9.7°) were machined using the metal-wire-filled electrode and molten-metal-filled electrode, which could replace the traditional electrode, achieving a longer service life and superior sidewall-insulation performance.\u0000</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"11 3","pages":"509 - 522"},"PeriodicalIF":5.2,"publicationDate":"2023-03-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40436-022-00429-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44105415","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}

引用次数: 1

Coupling effect of micro-textured tools and cooling conditions on the turning performance of aluminum alloy 6061 微织构刀具与冷却条件对6061铝合金车削性能的耦合影响

IF 5.2 2区工程技术

Advances in Manufacturing Pub Date : 2023-03-13 DOI: 10.1007/s40436-022-00432-y

Guo-Liang Liu, Jin-Tao Zheng, Chuan-Zhen Huang, Shu-Feng Sun, Xin-Fu Liu, Long-Jie Dai, De-Xiang Wang, Xiang-Yu Wang

{"title":"Coupling effect of micro-textured tools and cooling conditions on the turning performance of aluminum alloy 6061","authors":"Guo-Liang Liu, Jin-Tao Zheng, Chuan-Zhen Huang, Shu-Feng Sun, Xin-Fu Liu, Long-Jie Dai, De-Xiang Wang, Xiang-Yu Wang","doi":"10.1007/s40436-022-00432-y","DOIUrl":"10.1007/s40436-022-00432-y","url":null,"abstract":"<div><p>Micro-texturing has been widely proven to be an effective technology for achieving sustainable machining. However, the performance of micro-textured tools under different cooling conditions, especially their coupling effect on machined surface integrity, was scarcely reported. In this paper, the non-textured, linear micro-grooved, and curvilinear micro-grooved inserts were used to turn aluminum alloy 6061 under dry, emulsion, and liquid nitrogen cryogenic cooling conditions. The coupling effects of different micro-textures and cooling conditions on cutting force, cutting temperature, and machined surface integrity, including the surface roughness, work hardening, and residual stress, were revealed and discussed in detail. Results indicated that the micro-grooved tools, especially the curvilinear micro-grooved tools, not only reduced the cutting force and cutting temperature, but also improved the machined surface integrity. In addition, the micro-grooved tools can cooperate with the emulsion or liquid nitrogen to reduce the cutting force, cutting temperature, and improve the machined surface integrity generally, although the combination of emulsion cooling condition and micro-grooved tools generated negative coupling effects on cutting forces and surface work hardening. Especially, the combination of curvilinear micro-grooved cutting tools and cryogenic cooling condition resulted in the lowest cutting force and cutting temperature, which generated the surface with low roughness, weak work hardening, and compressive residual stress.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"11 4","pages":"663 - 681"},"PeriodicalIF":5.2,"publicationDate":"2023-03-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45114839","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}

引用次数: 1

Application of sensor data based predictive maintenance and artificial neural networks to enable Industry 4.0 应用基于传感器数据的预测性维护和人工神经网络实现工业4.0

IF 5.2 2区工程技术

Advances in Manufacturing Pub Date : 2023-03-04 DOI: 10.1007/s40436-022-00433-x

Jon Martin Fordal, Per Schjølberg, Hallvard Helgetun, Tor Øistein Skjermo, Yi Wang, Chen Wang

{"title":"Application of sensor data based predictive maintenance and artificial neural networks to enable Industry 4.0","authors":"Jon Martin Fordal, Per Schjølberg, Hallvard Helgetun, Tor Øistein Skjermo, Yi Wang, Chen Wang","doi":"10.1007/s40436-022-00433-x","DOIUrl":"10.1007/s40436-022-00433-x","url":null,"abstract":"<div><p>\u0000Possessing an efficient production line relies heavily on the availability of the production equipment. Thus, to ensure that the required function for critical equipment is in compliance, and unplanned downtime is minimized, succeeding with the field of maintenance is essential for industrialists. With the emergence of advanced manufacturing processes, incorporating predictive maintenance capabilities is seen as a necessity. Another field of interest is how modern value chains can support the maintenance function in a company. Accessibility to data from processes, equipment and products have increased significantly with the introduction of sensors and Industry 4.0 technologies. However, how to gather and utilize these data for enabling improved decision making within maintenance and value chain is still a challenge. Thus, the aim of this paper is to investigate on how maintenance and value chain data can collectively be used to improve value chain performance through prediction. The research approach includes both theoretical testing and industrial testing. The paper presents a novel concept for a predictive maintenance platform, and an artificial neural network (ANN) model with sensor data input. Further, a case of a company that has chosen to apply the platform, with the implications and determinants of this decision, is also provided. Results show that the platform can be used as an entry-level solution to enable Industry 4.0 and sensor data based predictive maintenance.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"11 2","pages":"248 - 263"},"PeriodicalIF":5.2,"publicationDate":"2023-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40436-022-00433-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43574287","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}

引用次数: 2

An iterative blending integrating grinding force model considering grain size and dislocation density evolution 考虑晶粒尺寸和位错密度演变的迭代混合积分磨削力模型

IF 5.2 2区工程技术

Advances in Manufacturing Pub Date : 2023-03-04 DOI: 10.1007/s40436-023-00436-2

Zi-Shan Ding, Yun-Hui Zhao, Miao-Xian Guo, Wei-Cheng Guo, Chong-Jun Wu, Steven Y. Liang

{"title":"An iterative blending integrating grinding force model considering grain size and dislocation density evolution","authors":"Zi-Shan Ding, Yun-Hui Zhao, Miao-Xian Guo, Wei-Cheng Guo, Chong-Jun Wu, Steven Y. Liang","doi":"10.1007/s40436-023-00436-2","DOIUrl":"10.1007/s40436-023-00436-2","url":null,"abstract":"<div><p>The dynamic force load in grinding process is considered as a crucial factor affecting the quality of parts, and a better understanding of the mechanism of force generation is conducive to revealing the evolution of material microstructure more precisely. In this study, an iterative blending integrating grinding force model that comprehensively considers the impact of grain size and dislocation density evolution of the material is proposed. According to the grinding kinematics, the interaction of grit-workpiece is divided into rubbing, plowing, and chip formation stages in each grinding zone. On this basis, the evolution of material microstructure in the current chip formation stage will affect the rubbing force in the next grinding arc through flow stresses, which in turn will influence the total grinding force. Therefore, the flow stress models in rubbing and chip formation stages are firstly established, and then the dislocation density prediction model is established experimentally based on the characteristics of grain size. The effects of the evolution of grain size and dislocation density on the grinding forces during the grinding process are studied by means of iterative cycles. The results indicate that the implementation of an iterative blending scheme is instrumental in obtaining a higher accurate prediction of the grinding force and a deeper insight of the influence mechanisms of materials microstructure on grinding process.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"11 3","pages":"428 - 443"},"PeriodicalIF":5.2,"publicationDate":"2023-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43298397","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}

引用次数: 1

Stage identification and process optimization for fast drilling EDM of film cooling holes using KBSI method 基于KBSI方法的薄膜冷却孔快速电火花加工阶段识别与工艺优化

IF 5.2 2区工程技术

Advances in Manufacturing Pub Date : 2023-03-01 DOI: 10.1007/s40436-022-00434-w

Jian Wang, Xue-Cheng Xi, Ya-Ou Zhang, Fu-Chun Zhao, Wan-Sheng Zhao

{"title":"Stage identification and process optimization for fast drilling EDM of film cooling holes using KBSI method","authors":"Jian Wang, Xue-Cheng Xi, Ya-Ou Zhang, Fu-Chun Zhao, Wan-Sheng Zhao","doi":"10.1007/s40436-022-00434-w","DOIUrl":"10.1007/s40436-022-00434-w","url":null,"abstract":"<div><p>Fast drilling electrical discharge machining (EDM) is widely used in the manufacture of film cooling holes of turbine blades. However, due to the various hole orientations and severe electrode wear, it is relatively intricate to accurately and timely identify the critical moments such as breakout, hole completion in the drilling process, and adjust the machining strategy properly. Existing breakout detection and hole completion determination methods are not suitable for the high-efficiency and fully automatic production of film cooling holes, for they almost all depend on preset thresholds or training data and become less appropriate when machining condition changes. As the breakout and hole completion detection problems can be abstracted to an online stage identification problem, in this paper, a kurtosis-based stage identification (KBSI) method, which uses a novel normalized kurtosis to denote the recent changing trends of gap voltage signals, is developed for online stage identification. The identification accuracy and generalization ability of the KBSI method have been verified in various machining conditions. To improve the overall machining efficiency, the influence of servo control parameters on machining efficiency of each machining stage was analyzed experimentally, and a new stage-wise adaptive control strategy was then proposed to dynamically adjust the servo control parameters according to the online identification results. The performance of the new strategy is evaluated by drilling film cooling holes at different hole orientations. Experimental results show that with the new control strategy, machining efficiency and the machining quality can be significantly improved.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"11 3","pages":"477 - 491"},"PeriodicalIF":5.2,"publicationDate":"2023-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45534602","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}

引用次数: 1

Identification of nonlinear process described by neural fuzzy Hammerstein-Wiener model using multi-signal processing 基于多信号处理的神经模糊Hammerstein—Wiener模型描述的非线性过程辨识

IF 5.2 2区工程技术

Advances in Manufacturing Pub Date : 2023-02-23 DOI: 10.1007/s40436-022-00426-w

Feng Li, Li Jia, Ya Gu

{"title":"Identification of nonlinear process described by neural fuzzy Hammerstein-Wiener model using multi-signal processing","authors":"Feng Li, Li Jia, Ya Gu","doi":"10.1007/s40436-022-00426-w","DOIUrl":"10.1007/s40436-022-00426-w","url":null,"abstract":"<div><p>In this study, a novel approach for nonlinear process identification via neural fuzzy-based Hammerstein-Wiener model with process disturbance by means of multi-signal processing is presented. The Hammerstein-Wiener model consists of three blocks where a dynamic linear block is sandwiched between two static nonlinear blocks. Multi-signal sources are designed for achieving identification separation of the Hammerstein-Wiener process. The correlation analysis theory is utilized for estimating unknown parameters of output nonlinearity and linear block using separable signals, thus the interference of process disturbance is solved. Furthermore, the immeasurable intermediate variable and immeasurable noise term in identification model is taken over by auxiliary model output and estimate residuals, and then auxiliary model-based recursive extended least squares parameter estimation algorithm is derived to calculate parameters of the input nonlinearity and noise model. Finally, convergence analysis of the suggested identification scheme is derived using stochastic process theory. The simulation results indicate that proposed identification approach yields high identification accuracy and has good robustness.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"11 4","pages":"694 - 707"},"PeriodicalIF":5.2,"publicationDate":"2023-02-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41564758","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}

引用次数: 4