International Journal of Machine Tools & Manufacture最新文献

{"title":"On-line laser shielding of hydrogen-induced pores in arc-directed energy deposition","authors":"Qinghu Guo ,&nbsp;Yangyi Pan ,&nbsp;Yili Wang ,&nbsp;Shiwei Hua ,&nbsp;Ling Cen ,&nbsp;Ming Gao ,&nbsp;Xinyuan Jin ,&nbsp;Xianfeng Li ,&nbsp;Chen Zhang ,&nbsp;Sheng Liu","doi":"10.1016/j.ijmachtools.2025.104279","DOIUrl":"10.1016/j.ijmachtools.2025.104279","url":null,"abstract":"<div><div>The detrimental effects of pollutant elements in arc-directed energy deposition (arc-DED), particularly hydrogen-induced porosity in aluminum alloys, pose critical challenges for structural integrity. While pollutant shielding is commonly employed for pore suppression, the risk of hydrogen contamination from repeated remelting of deposited layers remains largely overlooked. This study revealed that even trace surface oxides on deposited layers critically governed hydrogen pore nucleation. Microstructural characterization demonstrated a synergistic clustering mechanism among oxides, hydrogen, and pores, where oxides act as dual-functional sites for hydrogen carriers and trappers. To address this, we developed an innovative on-line laser shielding-enhanced arc-DED system integrating a high-frequency nanosecond pulsed laser with arc plasma. This hybrid approach achieved in situ oxide purification within the molten pool, reducing porosity by 98.1 % compared to conventional arc-DED. The laser-arc synergy demonstrated amplified shielding efficiency, with the arc plasma enhancing laser-induced oxide removal rate by 9.6 times. Crucially, this technology disrupted the oxide-mediated hydrogen transportation pathway while eliminating hydrogen-trapping effects in the molten pool. Implementation in Al-Zn-Mg-Cu alloys significantly improves ductility by minimizing porosity at deformation-sensitive interlayer regions. Process scalability was further verified in Al-Mg alloys, achieving comparable porosity reduction. By decoupling the dual roles of oxides in hydrogen carriers and trappers, this work establishes a paradigm-shifting strategy for pore control in arc-DED, offering a versatile platform for processing hydrogen/oxygen-sensitive metals with enhanced mechanical performance.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104279"},"PeriodicalIF":14.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143851790","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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 strength-ductility synergy in laser directed energy deposited IN718 superalloys through heterogeneous deformation nanostructures","authors":"Yao Li ,&nbsp;Mengyang Li ,&nbsp;Hao Yang ,&nbsp;Xiaofeng Dang ,&nbsp;Luqing Cui ,&nbsp;Yang Jiao ,&nbsp;Zhiping Sun ,&nbsp;Ting Guo ,&nbsp;Weifeng He","doi":"10.1016/j.ijmachtools.2025.104280","DOIUrl":"10.1016/j.ijmachtools.2025.104280","url":null,"abstract":"<div><div>Laser directed energy deposition (LDED) shows great promise for repairing superalloy components of aeroengines but often results in coarse microstructures, porosity, and tensile residual stresses. Herein, post-process ultrasonic impact treatment (UIT) is adopted to effectively regulate the surface microstructure and residual stresses in LDED-fabricated IN718 superalloys, enhancing the strength-ductility synergy. The UIT process optimization is achieved through a systematic investigation of the effect of output powers on surface roughness, porosity, deformation microstructure, microhardness distribution, residual stress profile, and tensile behavior. Particularly, a finite element model for simulating residual stress field induced by ultrasonic impact is established, showcasing excellent agreement with experimental measurements. UIT-induced substantial dislocation and twinning activities result in depth-dependent heterogeneous deformation nanostructures, including alternating nano-grains and nano-laminated composite structures on the top surface (&lt;8 μm), dense nanotwins (∼30 μm depth), and substantial dislocation tangles and pile-ups (∼150 μm depth). Compared to untreated samples, the yield strength of the samples treated with optimal UIT parameters increased by ∼40%, with negligible ductility loss. The synergistic strengthening mechanisms are mainly attributed to the work hardening and boundary strengthening. To decouple these effects, a quantitative framework that correlates with depth-dependent dislocation populations and grain/nanotwin sizes is proposed, demonstrating good consistency with experimental measurements. The preserved ductility stems from a macroscopic deformation delocalization strategy facilitated by the hetero-deformation induced stress, compressive residual stress, and reduced porosity, together with the near-surface heterogeneous nanostructures enabling deformation accommodation at the micro-scale. This work elucidates the enhanced strength-ductility synergy through surface heterogeneous nanostructures and provides practical guidance for the additive manufacturing of high-performance materials.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104280"},"PeriodicalIF":14.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859343","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Single-sensor-based reconstruction of force and displacement fields for thin-walled cylindrical shells milling","authors":"Jie Chen ,&nbsp;Haifeng Ma ,&nbsp;Qinghua Song ,&nbsp;Yukui Cai ,&nbsp;Zhanqiang Liu","doi":"10.1016/j.ijmachtools.2025.104282","DOIUrl":"10.1016/j.ijmachtools.2025.104282","url":null,"abstract":"<div><div>The cutting process of thin-walled cylindrical shells involves complex working conditions, and it is difficult to measure the cutting force and vibration displacement at the cutting point in real time. To address this issue, a method is proposed to reconstruct the force and displacement fields of the cylindrical shell in real time using only a single displacement sensor. Based on the first-order shear deformation theory and the artificial spring technique, the wave method can be employed to simultaneously obtain the natural frequencies and analytical mode shape functions of the cylindrical shell with elastic boundary. The dynamic behavior of the cylindrical shell is characterized by the superposition of mode shapes, thereby determining the force-displacement mapping relationship for the entire cylindrical shell. Utilizing in-situ measurement, the time-varying force and displacement fields are reconstructed in real time. Unlike existing methods for reconstructing the displacement field of thin-walled workpieces, one unique feature of this study is the simultaneous real-time reconstruction of the force and the displacement fields using single-point measurement information, providing higher reconstruction accuracy with fewer sensors, thus ensuring practicality and reliability of the results. Through simulation and experimental application to the force and displacement fields reconstruction of cylindrical shell under concentrated and moving force (e.g., cutting process), its practicality as a real-time tool for continuously monitoring cutting force and displacement of cylindrical shell during the cutting process has been demonstrated.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104282"},"PeriodicalIF":14.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143904261","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Towards understanding the polishing behavior of thin anisotropic crystals: Coupling, discrepancy, and control across scales","authors":"Wei Gao ,&nbsp;Caoyang Xue ,&nbsp;Qi Sun ,&nbsp;Fang Han ,&nbsp;Bing-Feng Ju ,&nbsp;Li-tian Xuan ,&nbsp;Junjie Zhang ,&nbsp;Wule Zhu","doi":"10.1016/j.ijmachtools.2025.104269","DOIUrl":"10.1016/j.ijmachtools.2025.104269","url":null,"abstract":"<div><div>Thin anisotropic crystals (TACs) have potential applications in semiconductors, microelectronics, and aerospace. However, polishing a TAC workpiece with a compliant tool is highly challenging because of its susceptibility to deformation and brittle damage owing to its thin structure. Another significant challenge for polishing is the anisotropic discrepancy, which is highly dependent on the crystal planes/directions. To address these challenges and ultimately realize the process control of polishing a TAC workpiece, this study establishes a comprehensive multiscale modeling framework. The proposed framework analytically incorporates the macroscale tool–TAC interaction mechanics, macro/micro coupling material removal mechanism, and macro/micro coupling subsurface damage behavior according to the physical properties of a TAC workpiece. Experiments at different scales are conducted to validate notable discrepancies in the surface and subsurface material responses in the polishing of a TAC workpiece, agreeing well with analytical predictions. Based on the cross-scale study and framework, space- and time-domain control strategies are proposed, demonstrating the capability for effectively eliminating the anisotropic discrepancy from macro- to microscale and enabling deterministic control in the polishing of TACs.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"207 ","pages":"Article 104269"},"PeriodicalIF":14.0,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143739024","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Defects in metal-forming: Formation mechanism, prediction and avoidance","authors":"Jun Ma ,&nbsp;Xuefeng Tang ,&nbsp;Yong Hou ,&nbsp;Heng Li ,&nbsp;Jianguo Lin ,&nbsp;M.W. Fu","doi":"10.1016/j.ijmachtools.2025.104268","DOIUrl":"10.1016/j.ijmachtools.2025.104268","url":null,"abstract":"<div><div>Defects in metal-forming create numerous bottleneck issues related to product quality, properties and performance, productivity, production cost, and sustainability. Effectively addressing defect issues in the up-front design process via prediction and avoidance of defect formation is the most critical and challenging issue in metal-forming based product development. In this paper, vital insights into defect classification, formation mechanisms, modelling/prediction, and avoidance principles and strategies in metal-forming are orchestrated and articulated. First, almost all the potential defects in metal-forming are exemplified and classified into three categories, viz., stress-induced, flow-induced, and microstructure-related defects. For each defect category, its influencing factors, formation mechanisms, and analysis approaches are delineated. Additionally, the countermeasures are articulated from the aspects of defect identification, control, avoidance or elimination by employing different state-of-the-art techniques, including in-process sensing/monitoring/detection, data-based modelling and online adaptive control. Finally, perspective insights into defect analysis, modelling/prediction, and avoidance are orchestrated and presented, focusing on innovative process developments, real-time in-process monitoring, physics-informed and data-driven through-process modelling, and strategies for intelligent and sustainable manufacturing.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"207 ","pages":"Article 104268"},"PeriodicalIF":14.0,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143724294","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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":"Particle floating and transfer effect in cored wire arc additive manufacturing: Formation mechanism and laser shock inhibition","authors":"Le Jia,&nbsp;Hao Yi,&nbsp;Furui Jiao,&nbsp;Huajun Cao","doi":"10.1016/j.ijmachtools.2025.104260","DOIUrl":"10.1016/j.ijmachtools.2025.104260","url":null,"abstract":"<div><div>Multi-material wire arc additive manufacturing (WAAM) presents a promising approach for fabricating high-end equipment components, with cored wire arc additive manufacturing (CWAAM) attracting significant interest. However, uneven particle distribution in CWAAM impedes technological advancement, as the mechanisms of particle flotation and its suppression remain unexplored. To address this issue, a novel nickel alloy cored wire incorporating TiC particles was developed, and the mechanism of particle flotation was investigated for the first time. The results indicate that the cored wire exhibits excellent formability, with particle flotation attributed to unstable droplet transfer, particle overflow along the side seam, and density differences. Furthermore, a laser shock-assisted CWAAM method was introduced to suppress particle flotation. Laser shock generated shock waves in the molten pool, inducing significant oscillations. Shock wave propagation altered molten pool flow dynamics and particle motion, effectively suppressing particle flotation and mitigating defects. This resulted in uniform particle dispersion in the deposited layer and facilitated particle size reduction. Additionally, laser shock eliminated porosity and fusion defects caused by particle flotation. The average grain size of the deposition layer decreased by 34.5 % and 23.3 % compared to solid wire arc additive manufacturing (SWAAM) and CWAAM, respectively, with a more random grain orientation. The average microhardness reached 394.8 HV_0.3, exceeding that of the other two methods, with no significant distribution differences. Yield strength, ultimate tensile strength, and elongation increased by 7.71 %, 5.37 %, and 12.71 % in the horizontal direction, and by 18.62 %, 6.63 %, and 13.03 % in the longitudinal direction, respectively, compared to conditions without laser shock, effectively reducing performance anisotropy. This innovative laser shock-assisted CWAAM method effectively mitigates weakened reinforcement effects and defects caused by particle flotation, thereby advancing WAAM toward large-scale, multi-material, and high-performance manufacturing.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"207 ","pages":"Article 104260"},"PeriodicalIF":14.0,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143610192","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Covalently armoring graphene on diamond abrasives with unprecedented wear resistance and abrasive performance","authors":"Qiang Lin ,&nbsp;Sulin Chen ,&nbsp;Hongbin Li ,&nbsp;Zhengzong Sun ,&nbsp;Zhinan Zhang ,&nbsp;Martin Dienwiebel ,&nbsp;Michael Moseler ,&nbsp;Bin Shen","doi":"10.1016/j.ijmachtools.2025.104254","DOIUrl":"10.1016/j.ijmachtools.2025.104254","url":null,"abstract":"<div><div>Next-generation semiconductor materials, including diamond, SiC, and GaN, offer significant advantages for high-power devices. However, the high-performance polishing of these ultrahard materials is limited by insufficient grit wear resistance and low-quality material removal with conventional diamond abrasives. In this study, we report robust integration of flexible graphene armor on diamond abrasives through covalent interfacial bonding for high-efficiency high-quality polishing of ultrahard materials. Utilizing a novel Ga-diamond cellular wetting strategy followed by vacuum heating treatment, we achieved highly scalable production of graphene-armored diamond abrasives with a productivity of 1 kg/L. The employment of graphene-armored diamond abrasives simultaneously improved the polishing efficiency and polishing quality, enabling damage-free atomic-level surface finish and an atomic attrition rate 5 times greater than conventional diamond abrasives. This efficient material attrition is attributed to the robust combination of exceptional intrinsic wear resistance, bonding capability and high flexibility of graphene with the ultrahigh hardness of diamond. The synergy of soft graphene and hard diamond grit provides sufficient material removal capability while simultaneously reducing the polishing damage that is often induced by brittle fracture and extreme local contact pressure with conventional diamond abrasives. This work offers a novel solution that enables high-efficiency high-quality polishing of ultrahard materials with a room-temperature, chemical-free and low-cost mechanical polishing procedure.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"206 ","pages":"Article 104254"},"PeriodicalIF":14.0,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143348737","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Atomic-level insight into sequential evolution of nanocomposite carbon structures in femtosecond laser processing of diamond","authors":"Huili Han,&nbsp;Hao Liu,&nbsp;Jiaxu Huang,&nbsp;Pei Qiu,&nbsp;Jun Li,&nbsp;Bi Zhang,&nbsp;Shaolin Xu","doi":"10.1016/j.ijmachtools.2025.104247","DOIUrl":"10.1016/j.ijmachtools.2025.104247","url":null,"abstract":"<div><div>Diamond is an exceptional wide-bandgap semiconductor for electronics and quantum technologies. While femtosecond laser processing enables micro/nano fabrication of diamond, the dynamic atomic-level structural evolution during this process remains poorly understood, despite its critical impact on advanced applications. In this work, we investigate the multi-stage structural evolution of diamond under femtosecond laser irradiation, uncovering new scientific findings under laser-induced extreme conditions. The continuous input of pulse energy facilitates the rearrangement of local carbon atoms in the modified layer and partial phase transition layer, transitioning them from thermodynamically unstable to stable states. We introduce a sequential evolution pathway of nanocomposite carbon structures, and reinterpret the phenomenon previously broadly defined as “graphitization”. Specifically, the evolution of diaphite, diamond-OLC (onion-like carbon), and the transition from amorphous carbon to planar-oriented graphite are reported under femtosecond laser surface processing. These phase transitions are initiated by the rapid lattice heating, with their distribution influenced by near-field enhancement effects arisen from surface nanostructures. This work provides atomic-scale insights into diamond's response in femtosecond laser processing, offering a theoretical foundation for ultra-precision micro/nano fabrication of diamond and the development of functional carbon materials.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"206 ","pages":"Article 104247"},"PeriodicalIF":14.0,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157268","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimized dispersion of inorganic metal salts in photocurable resins for high-precision continuous 3D printing of complex metal structures","authors":"Dylan Joralmon,&nbsp;John Walling,&nbsp;Amal Rai,&nbsp;Xiangjia Li","doi":"10.1016/j.ijmachtools.2025.104259","DOIUrl":"10.1016/j.ijmachtools.2025.104259","url":null,"abstract":"<div><div>Emerging metal additive manufacturing (AM) technologies that incorporate metal precursors to fabricate both metal and alloy 3D objects has become an attractive method for producing complex metallic objects with microscale features. However, current metal precursor additive manufacturing technologies that operate in a layer-by-layer manner are limited by low solid loading, poor rheological performance, slow printing speed, and anisotropic physical properties from the stacking of individual layers. To circumvent these challenges, printing resin with high solid loading of metal precursors and excellent rheological behavior was developed and employed in a rapid, layer-less additive manufacturing process to fabricate metal precursor objects within minutes. Addition of BYK-2013 dispersant, an ionic copolymer, to aid in the homogeneous dispersion of metal salt precursor dispersion was able to achieve a high maximum copper precursor concentration of 60 % (w/w) while sustaining stable dispersion for more than 24 h without displaying significant particle sedimentation greater than 1 mm. Cross-linking characteristics were investigated to optimize surface quality and reduce printing times of 3D printed objects resulting in low surface roughness (0.986 μm) and printing speeds upwards of 20 μm s⁻¹. Additionally, experimental results indicated that resins containing BYK-2013 exhibited superior hydrophobicity with no rehydration of inorganic metal salts after 180 min while maintaining an excellent viscosity of approximately 0.16 Pa s. Thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) guided post-processing optimization was successfully conducted to promote stable thermal decomposition during the removal of organics, metal oxide formation, and metal oxide reduction leading to highly robust copper lattices with final concentration of copper upwards of 92.8 % and an overall average isotropic shrinkage of 62 %. Furthermore, the microstructure evinces that an either dense or porous microstructure can be realized by adjusting metal precursor concentration to generate tunable physical properties with the final copper part. This study provides a unique and cost-effective methodology for formulating photocurable metal precursor resins with exemplary rheological behavior to produce intricately designed metal and alloys for a wide range of industrial engineering applications.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"206 ","pages":"Article 104259"},"PeriodicalIF":14.0,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143465141","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel continuous dynamic recrystallization model to reveal grain refinement mechanism in constraining ring rolling of thin-walled conical structure with inner ribs","authors":"Fei Chen ,&nbsp;Xiao Tian ,&nbsp;Zixuan Liu ,&nbsp;Dongsheng Qian ,&nbsp;Xinghui Han ,&nbsp;Bing Wang ,&nbsp;He Wang ,&nbsp;Zhenshan Cui","doi":"10.1016/j.ijmachtools.2025.104255","DOIUrl":"10.1016/j.ijmachtools.2025.104255","url":null,"abstract":"<div><div>Constraining ring rolling (CRR) is an integral and near net-shape forming approach to fabricate the seamless ring aluminum components in aerospace field. The service property of the formed ring components mainly depends on the microscopical grain texture. However, investigation and modeling of microstructure evolution in this complex hot working processes are not appropriately performed, which hinders further control of the forming quality of components during CRR. In this study, by analyzing the characteristics of CRR process and deformation modes in different characteristic zones of typical thin-walled conical ring with inner transverse ribs (TWCRITRs), a continuous dynamic recrystallization (CDRX) model of aluminum alloy that considers the influence of thermal deformation history was firstly proposed. The developed CDRX model was integrated into the finite element (FE) to predict microstructure evolution throughout the entire hot working process. The optimal parameters of the CRR process were obtained with the uniformity and fineness of microstructure as the goal, guiding the subsequent forming experiment. The predicted shape and microstructure agree well with the experimental results. It is found that the grain refinement mechanisms of 2A14 Al-alloy TWCRITRs during CRR include CDRX and thin grain cutting CDRX. Due to the low-angle grain boundaries (LAGBs) being pinned by the upper and lower high-angle grain boundaries (HAGBs), the recrystallization efficiency in the thin grain cutting CDRX is higher than that in the traditional CDRX mechanism. The shear deformation at thin-wall and complex deformation at the corner promotes the occurrence of thin grain cutting CDRX mechanism with a higher recrystallization efficiency. Eventually, the mechanical properties of manufacturing TWCRITRs met the requirements. All of these provide additional insights into the shape and microstructure controlled CRR process for TWCRITRs.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"206 ","pages":"Article 104255"},"PeriodicalIF":14.0,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143421036","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}