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Experimental investigation of temperature field and formability of compact fused granulation fabrication barrel
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2025.01.009
Baolin Liu , Zibin Liu , Xianglong Li , Haokun Xiao , Jingting Deng , Shuxia Li , Yongqiang Yang , Huilin Liu , Changhui Song
To address the problems of material agglomeration caused by unreasonable temperature field in compact screw extruders, an original Heat Break-like Structure (HBS) was introduced to realize accurate zonal control of the temperature field within the barrel. A novel barrel was iteratively designed through temperature field simulation. The temperature gradient across the feeding zone can be linearly adjusted by altering the internal wall thickness and the external wall depth of HBS. After optimization, the overall length of the device was reduced by 30 %, and the temperature difference across feeding zone reached 30.9 °C, 6.92 times higher than that of traditional structure. In addition, the PLA material was formed by an iteratively optimized Fused Granulation Fabrication (FGF) barrel. The tensile strength reached 41.67 MPa when the feed temperature was 160 °C and the printing temperature was 195 °C. However, the tensile strength dropped to 34.25 MPa when the feed temperature was 155 °C and the printing temperature was 210 °C. The iterative development of this novel compact FGF device eliminates the need for filament preparation, simplifying the manufacturing process, and holds great significance for achieving a low-carbon economy.
{"title":"Experimental investigation of temperature field and formability of compact fused granulation fabrication barrel","authors":"Baolin Liu ,&nbsp;Zibin Liu ,&nbsp;Xianglong Li ,&nbsp;Haokun Xiao ,&nbsp;Jingting Deng ,&nbsp;Shuxia Li ,&nbsp;Yongqiang Yang ,&nbsp;Huilin Liu ,&nbsp;Changhui Song","doi":"10.1016/j.jmapro.2025.01.009","DOIUrl":"10.1016/j.jmapro.2025.01.009","url":null,"abstract":"<div><div>To address the problems of material agglomeration caused by unreasonable temperature field in compact screw extruders, an original Heat Break-like Structure (HBS) was introduced to realize accurate zonal control of the temperature field within the barrel. A novel barrel was iteratively designed through temperature field simulation. The temperature gradient across the feeding zone can be linearly adjusted by altering the internal wall thickness and the external wall depth of HBS. After optimization, the overall length of the device was reduced by 30 %, and the temperature difference across feeding zone reached 30.9 °C, 6.92 times higher than that of traditional structure. In addition, the PLA material was formed by an iteratively optimized Fused Granulation Fabrication (FGF) barrel. The tensile strength reached 41.67 MPa when the feed temperature was 160 °C and the printing temperature was 195 °C. However, the tensile strength dropped to 34.25 MPa when the feed temperature was 155 °C and the printing temperature was 210 °C. The iterative development of this novel compact FGF device eliminates the need for filament preparation, simplifying the manufacturing process, and holds great significance for achieving a low-carbon economy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 697-708"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131980","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}
引用次数: 0
Multi-objective optimization of LPBF manufacturing with Zn-4Al-1Cu alloy for technical applications
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.049
Alexander Heiss , Venkat Sai Thatikonda , Ulrich E. Klotz
Cost-utility analyses vary by application. Regarding laser powder bed fusion (LPBF) manufacturing with zinc for technical applications, however, quality, production costs, and sustainability require distinct evaluation. The narrow process window of LPBF with zinc alloys, due to their low melting point, poses challenges, yet dense parts (> 99 %) were successfully produced, albeit with high costs and occasional quality variations. Commercial LPBF manufacturing demands stable processes for consistent quality. A controlled porosity may be acceptable based on specifications. This study presents a multi-objective optimization of LPBF manufacturing with the Zn alloy Z410. We examined the microstructure and pore morphology of 45 test parts, and applied unsupervised machine learning with principal component analysis to evaluate the process parameter space for density, pore size, and shape, creating process maps. The optimal laser parameters were then used to fabricate a demonstrator as proof of concept.
{"title":"Multi-objective optimization of LPBF manufacturing with Zn-4Al-1Cu alloy for technical applications","authors":"Alexander Heiss ,&nbsp;Venkat Sai Thatikonda ,&nbsp;Ulrich E. Klotz","doi":"10.1016/j.jmapro.2024.12.049","DOIUrl":"10.1016/j.jmapro.2024.12.049","url":null,"abstract":"<div><div>Cost-utility analyses vary by application. Regarding laser powder bed fusion (LPBF) manufacturing with zinc for technical applications, however, quality, production costs, and sustainability require distinct evaluation. The narrow process window of LPBF with zinc alloys, due to their low melting point, poses challenges, yet dense parts (&gt; 99 %) were successfully produced, albeit with high costs and occasional quality variations. Commercial LPBF manufacturing demands stable processes for consistent quality. A controlled porosity may be acceptable based on specifications. This study presents a multi-objective optimization of LPBF manufacturing with the Zn alloy Z410. We examined the microstructure and pore morphology of 45 test parts, and applied unsupervised machine learning with principal component analysis to evaluate the process parameter space for density, pore size, and shape, creating process maps. The optimal laser parameters were then used to fabricate a demonstrator as proof of concept.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 193-206"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132268","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}
引用次数: 0
Acceleration of powder-bed-size thermal simulation considering scanning-path-scale through a pseudo-layer-wise equivalent heat flux model
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.057
Fan Chen, Dominik Kozjek, Conor Porter, Jian Cao
Part-scale modeling of the temperature field in metal powder bed additive manufacturing (AM) is critical for predicting mechanical properties of the AM-ed parts. Track-by-track heat transfer analysis is impractical due to the extensive number of layers and the intricate design of scan strategies for the heat source, particularly in the fabrication of specimen clusters or parts with complex geometry, where multiple regions in the powder bed are manufactured simultaneously. Many part-scale modeling approaches only focus on the thermal behavior of a single part without considering the thermal interaction from the surrounding parts to reduce computational cost. However, experimental observations have revealed that the temperature distribution along the building direction can vary among samples with identical local geometries. This discrepancy can be attributed to the heating effects from neighboring samples. In this study, we propose an integrated part-scale modeling framework that combines layer-wise equivalent heat flux attribution with layer-wise element activation. Before the layer-wise attribution, we justify the equivalent heat flux of individual layers through high-fidelity track-scale simulations. Unlike traditional heat transfer analysis for single parts, our analysis incorporates heat conduction effects through the powder bed between different fusion zones. The temperature data obtained from each equivalent layer using our approach shows consistency when compared to the experimental observations. This research presents an efficient, physically grounded method for modeling the thermal behavior of large AM specimen clusters, enhancing our understanding of temperature field evolution in AM and supporting the design of optimized scanning path strategies for large samples.
{"title":"Acceleration of powder-bed-size thermal simulation considering scanning-path-scale through a pseudo-layer-wise equivalent heat flux model","authors":"Fan Chen,&nbsp;Dominik Kozjek,&nbsp;Conor Porter,&nbsp;Jian Cao","doi":"10.1016/j.jmapro.2024.12.057","DOIUrl":"10.1016/j.jmapro.2024.12.057","url":null,"abstract":"<div><div>Part-scale modeling of the temperature field in metal powder bed additive manufacturing (AM) is critical for predicting mechanical properties of the AM-ed parts. Track-by-track heat transfer analysis is impractical due to the extensive number of layers and the intricate design of scan strategies for the heat source, particularly in the fabrication of specimen clusters or parts with complex geometry, where multiple regions in the powder bed are manufactured simultaneously. Many part-scale modeling approaches only focus on the thermal behavior of a single part without considering the thermal interaction from the surrounding parts to reduce computational cost. However, experimental observations have revealed that the temperature distribution along the building direction can vary among samples with identical local geometries. This discrepancy can be attributed to the heating effects from neighboring samples. In this study, we propose an integrated part-scale modeling framework that combines layer-wise equivalent heat flux attribution with layer-wise element activation. Before the layer-wise attribution, we justify the equivalent heat flux of individual layers through high-fidelity track-scale simulations. Unlike traditional heat transfer analysis for single parts, our analysis incorporates heat conduction effects through the powder bed between different fusion zones. The temperature data obtained from each equivalent layer using our approach shows consistency when compared to the experimental observations. This research presents an efficient, physically grounded method for modeling the thermal behavior of large AM specimen clusters, enhancing our understanding of temperature field evolution in AM and supporting the design of optimized scanning path strategies for large samples.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 394-409"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131700","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}
引用次数: 0
Investigation of electrical-assisted micro-pattern forming process on Zircaloy-4 alloy surface
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.051
Tong Niu, Yuanxin Luo, Yang Luo, Lei Zhang
Electrically-assisted forming is a promising process to improving the plastic forming ability, which has attracted much attention in the fabrication of high-density micro textures. However, few studies have been devoted to quantify the effect of electric current on the micro textures forming process on large-area metal surfaces, especially zirconium alloys. In this paper, the performance of electrically-assisted micro-pattern process on forming high-density micro dimples on the surface of zirconium alloy is investigated. In order to predict the effect of high current density on the forming ability of zirconium alloy, a constitutive model considering current and temperature is developed associated with the results of electrically-assisted tensile tests and constant temperature tensile tests. In order to quantitatively evaluate the effects of current density and temperature on the micro-pattern forming process, the electro-thermo-mechanical coupling finite element model is established through a subroutine that combines the constitutive model with the simulation process. Electrically-assisted micro-pattern forming experiments with various parameters are carried out, and results indicates that the depth of micro dimples fabricated by electrically-assisted micro-pattern forming is greater than traditional micro-pattern forming. The maximum error between the finite element model results and the experimental results is about 10 %, which proves that the established constitutive and finite element model can quantify the electrically-assisted micro-pattern forming process.
{"title":"Investigation of electrical-assisted micro-pattern forming process on Zircaloy-4 alloy surface","authors":"Tong Niu,&nbsp;Yuanxin Luo,&nbsp;Yang Luo,&nbsp;Lei Zhang","doi":"10.1016/j.jmapro.2024.12.051","DOIUrl":"10.1016/j.jmapro.2024.12.051","url":null,"abstract":"<div><div>Electrically-assisted forming is a promising process to improving the plastic forming ability, which has attracted much attention in the fabrication of high-density micro textures. However, few studies have been devoted to quantify the effect of electric current on the micro textures forming process on large-area metal surfaces, especially zirconium alloys. In this paper, the performance of electrically-assisted micro-pattern process on forming high-density micro dimples on the surface of zirconium alloy is investigated. In order to predict the effect of high current density on the forming ability of zirconium alloy, a constitutive model considering current and temperature is developed associated with the results of electrically-assisted tensile tests and constant temperature tensile tests. In order to quantitatively evaluate the effects of current density and temperature on the micro-pattern forming process, the electro-thermo-mechanical coupling finite element model is established through a subroutine that combines the constitutive model with the simulation process. Electrically-assisted micro-pattern forming experiments with various parameters are carried out, and results indicates that the depth of micro dimples fabricated by electrically-assisted micro-pattern forming is greater than traditional micro-pattern forming. The maximum error between the finite element model results and the experimental results is about 10 %, which proves that the established constitutive and finite element model can quantify the electrically-assisted micro-pattern forming process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 452-465"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131763","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}
引用次数: 0
In-situ fabrication and coating of oxide-dispersion-strengthened AlCoCrFeNi2.1 composite powders: Microstructure, mechanism, and properties
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.035
Peng Wang , Xianglin Zhou , Zhipei Chen , Yudong Liang , Yu Shi , Mina Zhang , Xianglong Wang , Jian Sun , Zhiyong Yu , Xinggang Li
To produce next-generation bonded coating composites for extremely high-speed laser cladding (EHLC) applications, there is an urgent demand to overcome the problems of spherical composite powder manufacturing. Here, we produced oxide-dispersion-strengthened (ODS) AlCoCrFeNi2.1 eutectic high-entropy alloy (EHEA) composite powders in situ under different microaerobic conditions by gas atomization. The microaerobic conditions were regulated by the vacuum pressure (10−1 Pa, 10 Pa, 20 Pa, and 30 Pa) before alloy melting. We also investigated the microstructures, properties, and in-situ oxidation mechanisms of the corresponding powders and coatings. The results showed that stable Y2Hf2O7 particles and unstable Y2HfO5 striped oxides were formed in-situ at the L12-B2 phase interface in the Y/Hf co-doped AlCoCrFeNi2.1 EHEA powders fabricated under microaerobic conditions. As the amount of oxygen was increased, the amount and size of the oxides in the powder also increased, which was accompanied by a transition in the oxide morphology from nanoparticles to a reticulated structure due to a higher O2 diffusion rate in the coating. Additionally, a further transformation of the Y2HfO5 phase to the Y2Hf2O7 phase occurred due to the secondary diffusion of O2 during coating solidification. Compared with P = 10−1 Pa, upon increasing the amount of oxygen by increasing the vacuum pressure from 10 Pa to 30 Pa, the oxidation rate constants of the corresponding coatings at 1100 °C increased by 1063.9 %, 80.3 %, and 16.4 %, whereas the spallation rates increased by 4847.7 %, 98.7 %, and 29.5 %, respectively. The coatings obtained at P = 10−1 Pa showed superior high-temperature oxidation resistance compared with conventional NiCoCrAlY coatings.
{"title":"In-situ fabrication and coating of oxide-dispersion-strengthened AlCoCrFeNi2.1 composite powders: Microstructure, mechanism, and properties","authors":"Peng Wang ,&nbsp;Xianglin Zhou ,&nbsp;Zhipei Chen ,&nbsp;Yudong Liang ,&nbsp;Yu Shi ,&nbsp;Mina Zhang ,&nbsp;Xianglong Wang ,&nbsp;Jian Sun ,&nbsp;Zhiyong Yu ,&nbsp;Xinggang Li","doi":"10.1016/j.jmapro.2024.12.035","DOIUrl":"10.1016/j.jmapro.2024.12.035","url":null,"abstract":"<div><div>To produce next-generation bonded coating composites for extremely high-speed laser cladding (EHLC) applications, there is an urgent demand to overcome the problems of spherical composite powder manufacturing. Here, we produced oxide-dispersion-strengthened (ODS) AlCoCrFeNi<sub>2.1</sub> eutectic high-entropy alloy (EHEA) composite powders <em>in situ</em> under different microaerobic conditions by gas atomization. The microaerobic conditions were regulated by the vacuum pressure (10<sup>−1</sup> Pa, 10 Pa, 20 Pa, and 30 Pa) before alloy melting. We also investigated the microstructures, properties, and <em>in-situ</em> oxidation mechanisms of the corresponding powders and coatings. The results showed that stable Y<sub>2</sub>Hf<sub>2</sub>O<sub>7</sub> particles and unstable Y<sub>2</sub>HfO<sub>5</sub> striped oxides were formed <em>in-situ</em> at the L1<sub>2</sub>-B2 phase interface in the Y/Hf co-doped AlCoCrFeNi<sub>2.1</sub> EHEA powders fabricated under microaerobic conditions. As the amount of oxygen was increased, the amount and size of the oxides in the powder also increased, which was accompanied by a transition in the oxide morphology from nanoparticles to a reticulated structure due to a higher O<sub>2</sub> diffusion rate in the coating. Additionally, a further transformation of the Y<sub>2</sub>HfO<sub>5</sub> phase to the Y<sub>2</sub>Hf<sub>2</sub>O<sub>7</sub> phase occurred due to the secondary diffusion of O<sub>2</sub> during coating solidification. Compared with <em>P</em> = 10<sup>−1</sup> Pa, upon increasing the amount of oxygen by increasing the vacuum pressure from 10 Pa to 30 Pa, the oxidation rate constants of the corresponding coatings at 1100 °C increased by 1063.9 %, 80.3 %, and 16.4 %, whereas the spallation rates increased by 4847.7 %, 98.7 %, and 29.5 %, respectively. The coatings obtained at <em>P</em> = 10<sup>−1</sup> Pa showed superior high-temperature oxidation resistance compared with conventional NiCoCrAlY coatings.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 60-78"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131879","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}
引用次数: 0
Effects on microstructure and mechanical properties of aluminum alloy 6061 processed via underwater additive friction stir deposition
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2025.01.006
R.P. Kinser , N. Zhu , M.B. Williams , T.W. Rushing , K.J. Doherty , P.G. Allison , J.B. Jordon
Solid-state methods such as additive friction stir deposition (AFSD) have shown potential for the repair and bulk manufacture of precipitation-strengthened aluminum alloys, but most studies conducted with ambient air cooling have reported reductions in strength in the deposited material and underlying substrate. The present study investigates the effects of rapid heat dissipation in AFSD by conducting the entire deposition process underwater. Two depositions with the same process parameters and different cooling conditions are investigated, with subsequent comparisons highlighting differences in deposition morphology, mechanical properties, and microstructure. Microstructure characterization revealed significant grain refinement associated with the submerged cooling approach but a reduction in hardness and tensile strength compared to ambient conditions. The results of this study presented herein suggest that cooling the deposition in-situ can modify the deposition shape, induce less overall thermal degradation of the substrate, and produce superior grain refinement relative to ambient cooling conditions.
{"title":"Effects on microstructure and mechanical properties of aluminum alloy 6061 processed via underwater additive friction stir deposition","authors":"R.P. Kinser ,&nbsp;N. Zhu ,&nbsp;M.B. Williams ,&nbsp;T.W. Rushing ,&nbsp;K.J. Doherty ,&nbsp;P.G. Allison ,&nbsp;J.B. Jordon","doi":"10.1016/j.jmapro.2025.01.006","DOIUrl":"10.1016/j.jmapro.2025.01.006","url":null,"abstract":"<div><div>Solid-state methods such as additive friction stir deposition (AFSD) have shown potential for the repair and bulk manufacture of precipitation-strengthened aluminum alloys, but most studies conducted with ambient air cooling have reported reductions in strength in the deposited material and underlying substrate. The present study investigates the effects of rapid heat dissipation in AFSD by conducting the entire deposition process underwater. Two depositions with the same process parameters and different cooling conditions are investigated, with subsequent comparisons highlighting differences in deposition morphology, mechanical properties, and microstructure. Microstructure characterization revealed significant grain refinement associated with the submerged cooling approach but a reduction in hardness and tensile strength compared to ambient conditions. The results of this study presented herein suggest that cooling the deposition in-situ can modify the deposition shape, induce less overall thermal degradation of the substrate, and produce superior grain refinement relative to ambient cooling conditions.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 932-942"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132046","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}
引用次数: 0
Bionic stepped drilling and milling composite tool based on beetle mouthparts: A comprehensive analysis of machining mechanism and cutting performance
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.041
Tong Ma , Wentian Shi , Jian Han , Jie Li , Biao Guo , Jianing Li , Lin Wang , Tianming Yan
Aramid fiber-reinforced polymer (AFRP), as a high-tech composite material with excellent performance, is widely used in the aerospace field, but it is prone to producing more machining defects in the drilling process, which seriously restricts the manufacturing accuracy and machining efficiency of the parts. In order to reduce the drilling damage of AFRP, a model of cutting of delamination damage was founded, the influencing factors of fibroid deformation were investigated, and a functional relationship between deformation and drilling force was acquired. On this basis, the cutting machining mechanism of the end mill and the drilling bit was analyzed, a material removal method of “centering and scratching” was proposed, and a stepped control scheme of “drilling before milling” was determined. Based on the tooth profile morphology of the beetle mouthparts, three kinds of tool structures with different rake angles were designed, the machining mechanism of the new cutters was researched, and comparative tests with various cutting tools and machining conditions were conducted. The research results showed that the new tools changed the removal mechanisms of the AFRP composite material within the cutting machining process of conventional tools and could reduce the cutting force while suppressing the delamination damage. Among them, the 45° rake angle tool showed excellent cutting performance. The machining effects of burr-free holes, low delamination factor, and low tool wear were achieved within the range of test parameters. In addition, the cutting force was also lower, with a magnitude of 47.267% of the milling force of an end mill and only 28.309% of that of a drill bit. However, against the situation of minimum quantity lubrication (MQL), the cutting machining force increased significantly, which was about 4.706 times that of the dry cutting test. The surface morphology was poor at this time, and the tool wear increased. In summary, the research content of this article will provide new ideas and methods for low-damage machining and specialized tool design of AFRP, and further clarify the cutting mechanism of this material under dry cutting and MQL machining conditions.
{"title":"Bionic stepped drilling and milling composite tool based on beetle mouthparts: A comprehensive analysis of machining mechanism and cutting performance","authors":"Tong Ma ,&nbsp;Wentian Shi ,&nbsp;Jian Han ,&nbsp;Jie Li ,&nbsp;Biao Guo ,&nbsp;Jianing Li ,&nbsp;Lin Wang ,&nbsp;Tianming Yan","doi":"10.1016/j.jmapro.2024.12.041","DOIUrl":"10.1016/j.jmapro.2024.12.041","url":null,"abstract":"<div><div>Aramid fiber-reinforced polymer (AFRP), as a high-tech composite material with excellent performance, is widely used in the aerospace field, but it is prone to producing more machining defects in the drilling process, which seriously restricts the manufacturing accuracy and machining efficiency of the parts. In order to reduce the drilling damage of AFRP, a model of cutting of delamination damage was founded, the influencing factors of fibroid deformation were investigated, and a functional relationship between deformation and drilling force was acquired. On this basis, the cutting machining mechanism of the end mill and the drilling bit was analyzed, a material removal method of “centering and scratching” was proposed, and a stepped control scheme of “drilling before milling” was determined. Based on the tooth profile morphology of the beetle mouthparts, three kinds of tool structures with different rake angles were designed, the machining mechanism of the new cutters was researched, and comparative tests with various cutting tools and machining conditions were conducted. The research results showed that the new tools changed the removal mechanisms of the AFRP composite material within the cutting machining process of conventional tools and could reduce the cutting force while suppressing the delamination damage. Among them, the <span><math><msup><mn>45</mn><mo>°</mo></msup></math></span> rake angle tool showed excellent cutting performance. The machining effects of burr-free holes, low delamination factor, and low tool wear were achieved within the range of test parameters. In addition, the cutting force was also lower, with a magnitude of <span><math><mn>47.267</mn><mo>%</mo></math></span> of the milling force of an end mill and only <span><math><mn>28.309</mn><mo>%</mo></math></span> of that of a drill bit. However, against the situation of minimum quantity lubrication (MQL), the cutting machining force increased significantly, which was about <span><math><mn>4.706</mn></math></span> times that of the dry cutting test. The surface morphology was poor at this time, and the tool wear increased. In summary, the research content of this article will provide new ideas and methods for low-damage machining and specialized tool design of AFRP, and further clarify the cutting mechanism of this material under dry cutting and MQL machining conditions.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 263-284"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132200","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}
引用次数: 0
Microstructure evolution of titanium alloy under direct pulse current electromagnetic forming
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.062
Fei Feng , Rongchuang Chen , Linfeng Du , Li Yang
Titanium alloy has high deformation resistance and low electrical conductivity, so it is difficult to form by traditional electromagnetic forming (TEMF) at room temperature. Direct pulse current electromagnetic forming (DPCEMF) simultaneously combines electromagnetic forming and pulse current heating. This study investigates the microstructure evolution and deformation mechanism of titanium alloy sheet during DPCEMF through the microscopic characterization. Results show that the β phase volume fraction of DPCEMF-0.3 enhanced 262.5 % compared with that of TEMF-0.3. The KAM distribution of DPCEMF-0.3 is uniform and average KAM value is obviously smaller compared to the TEMF-0.3, which is indicated that the dislocation density decreases in DPCEMF. And the average Schmidt factor value of DPCEMF-0.3 specimen is larger than the TEMF-0.3, indicating a more favorable slip system activating in the DPCEMF. Although the electromagnetic field and high strain rate deformation could accelerate phase transition during the DPCEMF, the most important factor that promoted the phase transition was the electric pulse and thermal effects. The drift electrons of pulse current can push dislocations when the high density pulse current passes through the DPCEMF specimen, reduce the dislocation density, and enhance dislocation mobility. At the same time, the dynamic recrystallization inhibited directional grain growth, resulting in a large reduction in texture strength and a diffused orientation. The deformation mechanism of DPCEMF is dislocation plane-slip. The main softening mechanisms of DPCEMF are electropulsing thermal effect and dynamic recrystallization.
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引用次数: 0
Spatial mechanical enhancement strategy enabled by multi-axis material extrusion additive manufacturing
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2025.01.002
Ze Zhang , Kewei Song , Yifan Pan , Jianxian He , Shinjiro Umezu
Material extrusion (ME) is one of the most widely used additive manufacturing (AM) methods, but its application is often constrained by the weak interlayer bonding inherent in the layer-by-layer deposition process. To address this limitation, we propose a multi-degree-of-freedom (MDOF) spatial enhancement strategy for material extrusion additive manufacturing. This strategy defines models into core and reinforcement layers at the design stage and utilizes a six-axis printer to achieve spatial anisotropy, significantly improving the overall mechanical properties of printed parts. Mechanical tests reveal that the core layer ratio, the angle between reinforcement and core layer rasters, and the reinforcement layer fill rate have a pronounced impact on tensile, compressive, and bending performance. Scanning electron microscopy (SEM) analysis further elucidates the fracture mechanisms and strengthening effects. The results demonstrate that a core layer ratio of 5:5, a reinforcement angle of 90°, and a fill rate of 90 % yield optimal mechanical performance in standard specimens, while varying these parameters offers insights into potential practical applications. Moreover, the proposed spatial enhancement strategy effectively addresses the issue of low reliability in the mechanical properties along the layer accumulation direction under various operating conditions in traditional ME processes. It expands the applicability of ME process in freeform surfaces and complex structures requiring balanced anisotropic mechanical performance. This strategy holds promise for advancing industrial applications in fields such as aerospace, automotive manufacturing, and biomedical engineering, while demonstrating feasibility for adoption on other multi-axis printing platforms.
{"title":"Spatial mechanical enhancement strategy enabled by multi-axis material extrusion additive manufacturing","authors":"Ze Zhang ,&nbsp;Kewei Song ,&nbsp;Yifan Pan ,&nbsp;Jianxian He ,&nbsp;Shinjiro Umezu","doi":"10.1016/j.jmapro.2025.01.002","DOIUrl":"10.1016/j.jmapro.2025.01.002","url":null,"abstract":"<div><div>Material extrusion (ME) is one of the most widely used additive manufacturing (AM) methods, but its application is often constrained by the weak interlayer bonding inherent in the layer-by-layer deposition process. To address this limitation, we propose a multi-degree-of-freedom (MDOF) spatial enhancement strategy for material extrusion additive manufacturing. This strategy defines models into core and reinforcement layers at the design stage and utilizes a six-axis printer to achieve spatial anisotropy, significantly improving the overall mechanical properties of printed parts. Mechanical tests reveal that the core layer ratio, the angle between reinforcement and core layer rasters, and the reinforcement layer fill rate have a pronounced impact on tensile, compressive, and bending performance. Scanning electron microscopy (SEM) analysis further elucidates the fracture mechanisms and strengthening effects. The results demonstrate that a core layer ratio of 5:5, a reinforcement angle of 90°, and a fill rate of 90 % yield optimal mechanical performance in standard specimens, while varying these parameters offers insights into potential practical applications. Moreover, the proposed spatial enhancement strategy effectively addresses the issue of low reliability in the mechanical properties along the layer accumulation direction under various operating conditions in traditional ME processes. It expands the applicability of ME process in freeform surfaces and complex structures requiring balanced anisotropic mechanical performance. This strategy holds promise for advancing industrial applications in fields such as aerospace, automotive manufacturing, and biomedical engineering, while demonstrating feasibility for adoption on other multi-axis printing platforms.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 762-774"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131947","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}
引用次数: 0
Sweating type surface grinding wheels for self-adaptable lubricant delivery governed by cutting temperature and speed
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.081
Sarath Babu Thekkoot Surendran, V.S. Sooraj
Thermo-regulation in grinding operation is of great research interest, especially while dealing with difficult-to-cut aerospace materials. While the green and sustainable practices demand a shift towards dry or near dry machining, smart mechanisms for the controlled delivery of lubricant to manage the generation of heat flux in the grinding zone is a research gap that pulls attraction. This paper addresses such a development in the form of a modular type grinding wheel with the ability to ‘sweat’ according to the variation of temperature at the grinding zone. The potential capabilities of additive manufacturing (3D printing) are used for the proposed configuration with a reusable inner core and replaceable abrasive segments. The wheel is designed with in-situ fluid reservoirs, facilitating its flow through porous restrictors for a self-adaptable delivery of lubricant droplets according to the variations in cutting interface temperature and as a function of cutting speed. Mathematical models and numerical simulations to understand the process variables have been included for this newly developed system. Performance studies of sweating wheel conducted on Ti6Al4V shown typical reduction in grinding temperature, force, and roughness (58 %, 37 % and 16 %, respectively), at a cutting speed of 1884 m/min and depth of cut of 20 μm, in comparison with the flood cooling of super abrasive (CBN) wheels. Thus, the proposed wheel is recommended to be a futuristic smart industrial solution for thermo-regulation in grinding achieved via the capabilities of additive manufacturing.
{"title":"Sweating type surface grinding wheels for self-adaptable lubricant delivery governed by cutting temperature and speed","authors":"Sarath Babu Thekkoot Surendran,&nbsp;V.S. Sooraj","doi":"10.1016/j.jmapro.2024.12.081","DOIUrl":"10.1016/j.jmapro.2024.12.081","url":null,"abstract":"<div><div>Thermo-regulation in grinding operation is of great research interest, especially while dealing with difficult-to-cut aerospace materials. While the green and sustainable practices demand a shift towards dry or near dry machining, smart mechanisms for the controlled delivery of lubricant to manage the generation of heat flux in the grinding zone is a research gap that pulls attraction. This paper addresses such a development in the form of a modular type grinding wheel with the ability to ‘sweat’ according to the variation of temperature at the grinding zone. The potential capabilities of additive manufacturing (3D printing) are used for the proposed configuration with a reusable inner core and replaceable abrasive segments. The wheel is designed with in-situ fluid reservoirs, facilitating its flow through porous restrictors for a self-adaptable delivery of lubricant droplets according to the variations in cutting interface temperature and as a function of cutting speed. Mathematical models and numerical simulations to understand the process variables have been included for this newly developed system. Performance studies of sweating wheel conducted on Ti6Al4V shown typical reduction in grinding temperature, force, and roughness (58 %, 37 % and 16 %, respectively), at a cutting speed of 1884 m/min and depth of cut of 20 μm, in comparison with the flood cooling of super abrasive (CBN) wheels. Thus, the proposed wheel is recommended to be a futuristic smart industrial solution for thermo-regulation in grinding achieved via the capabilities of additive manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 915-931"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132048","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}
引用次数: 0
期刊
Journal of Manufacturing Processes
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