Journal of Manufacturing Processes最新文献_第2页

Oxidation and photothermal energy conversion at the laser-induced vapor–liquid interface during laser spot welding 激光点焊过程中气液界面氧化与光热能量转换

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-15 DOI: 10.1016/j.jmapro.2026.01.031

Tao Liu , Shun Xie , Jianglin Zou , Jing Wang , Kaikai Shi , Yuxuan Zhang , Qiang Wu

Studying the oxidation behavior on the molten pool surface during laser spot welding in an atmospheric environment is important for developing molten pool protection strategies and for understanding the laser-induced optical-to-thermal energy conversion at the vapor–liquid interface. This study shows that, under a fixed laser exposure duration, as the laser power increases, the solid-phase heating stage is markedly shortened, the melting stage first lengthens and then shortens, and the vaporization stage continues to extend. Meanwhile, the total laser absorptivity of the metal exhibits a non-monotonic trend, decreasing first and then increasing, and the absorptivity in air is consistently higher than that in argon. Under atmospheric conditions, surface oxidation of the molten pool occurs predominantly during the melting stage, where oxidation of the liquid surface can significantly enhance absorptivity. At low laser power without a vaporization stage, the prolonged melting stage leads to a peak absorptivity of the liquid surface in air that is approximately 14.7% higher than that in argon. At high laser power, laser-induced evaporation suppresses further surface oxidation, causing the absorptivity of the vapor–liquid interface to decrease with increasing power. In addition, the shortening of the melting stage with increasing high laser power is a primary reason why both the extent of surface oxidation and the corresponding absorptivity increment become negligible under atmospheric conditions. Overall, this work elucidates the stage-dependent roles of vapor–liquid interfacial oxidation during laser spot welding and provides a theoretical basis for improving energy coupling efficiency and for designing optimal molten pool protection strategies in high-precision laser melting manufacturing applications.

研究大气环境下激光点焊过程中熔池表面的氧化行为，对于制定熔池保护策略和理解激光诱导的气液界面光热转换具有重要意义。研究表明，在一定的激光照射时间下，随着激光功率的增大，固相加热阶段明显缩短，熔化阶段先变长后变短，汽化阶段持续延长。同时，金属的激光总吸收率呈先减小后增大的非单调趋势，在空气中的吸收率始终高于氩气中的吸收率。在大气条件下，熔池表面氧化主要发生在熔化阶段，此时液面氧化可显著提高吸收率。在没有汽化阶段的低激光功率下，熔化阶段延长导致液体表面在空气中的峰值吸收率比在氩气中的峰值高约14.7%。在高激光功率下，激光诱导的蒸发抑制了进一步的表面氧化，导致气液界面的吸收率随着功率的增加而降低。此外，随着激光功率的增加，熔化阶段的缩短是大气条件下表面氧化程度和相应的吸收率增量可以忽略不计的主要原因。总的来说，本研究阐明了激光点焊过程中气液界面氧化的阶段依赖作用，为高精度激光熔化制造应用中提高能量耦合效率和设计最佳熔池保护策略提供了理论基础。

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引用次数: 0

Plasticity improvement by pulsed electric current during sheet metal forming of Al-Mg alloy strips in different states of hardening 脉冲电流对不同硬化状态下铝镁合金带材成形塑性的改善

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-15 DOI: 10.1016/j.jmapro.2026.01.020

Daniel Dobras , Zbigniew Zimniak , Mateusz Dziubek

Aluminum alloys have high specific strength, which means that their use can result in a reduction in vehicle weight and thus their emissions. However, their formability at room temperature is low. A significant increase in the formability of strain-hardened aluminum alloys can be achieved by applying current pulses during their deformation. However, until now, it has not been possible to achieve this in sheet metal forming of aluminum alloys. This work shows that it is possible to increase the drawability of aluminum alloy sheets in the electrically-assisted deep drawing process. Eliminating the blank holder force during the process, using stainless steel dies and modular punch design enabled the heat transfer to be reduced and the appropriate temperature of the drawpiece to be obtained. Thanks to this, dynamic recovery was triggered while maintaining the mechanical properties of the material. The obtained results will allow the development of the electrically-assisted sheet metal forming, especially the deep drawing processes. The drawability of the material can be increased in these processes by using the economical method of applying current pulses.

铝合金具有很高的比强度，这意味着它们的使用可以减少车辆重量，从而减少排放。然而，它们在室温下的成形性较低。通过在变形过程中施加电流脉冲，可以显著提高应变硬化铝合金的成形性。然而，到目前为止，还不可能在铝合金的金属板成形中实现这一目标。这项工作表明，在电动辅助拉深工艺中，提高铝合金板的拉伸性是可能的。采用不锈钢模具和模块化冲床设计，消除了压边力，减少了热传递，获得了合适的拉拔件温度。因此，在保持材料机械性能的同时触发了动态恢复。所得结果将为电辅助板料成形，特别是深拉深成形的发展提供理论依据。在这些过程中，通过使用经济的方法施加电流脉冲，可以增加材料的拉伸性。

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引用次数: 0

Enhanced formability of age-hardened 2219 aluminum alloy: role of through-thickness stress and temperature synergy 时效硬化2219铝合金成形性能的提高：厚度应力和温度协同作用

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-15 DOI: 10.1016/j.jmapro.2026.01.018

Ye Tian , Wen Zhang , Xincun Zhuang , Zhen Zhao

The limited formability of age-hardened aluminum alloys at room temperature presents significant manufacturing challenges for fabricating complex components. This study systematically investigates the synergistic enhancement mechanism of through-thickness stress and forming temperature on the formability of age-hardened 2219 aluminum alloy. A flat-bottom stretching test platform integrated with through-thickness stress control and temperature regulation was developed to evaluate the limiting forming height (LFH) under varying thermo-mechanical conditions (75–225 °C, 0–180 MPa). Contrary to the commonly assumed monotonic relationship, the results reveal a critical threshold of through-thickness stress (Pc) for significant formability improvement. And the P_C decreases as the forming temperature increases. Below Pc, LFH exhibited negligible improvement. When stress exceeded Pc, LFH increased sharply. As the stress continues to increase, the enhancement effect on LFH gradually diminishes. Microstructural analysis indicated that through-thickness stress effectively reduces damage accumulation by inhibiting the fragmentation of precipitates and the growth of voids. The theoretical predictions for P_C closely align with experimental results under conditions where stress triaxiality shifts from positive to negative values. In hole-flanging applications, a through-thickness stress of 120 MPa increased flange height by 17.4% and reduces required forming temperatures by 25 °C. These findings provide not only a fundamental insight into the non-linear effect of through-thickness stress but also practical strategies for efficient forming of age-hardened aluminum alloys.

时效硬化铝合金在室温下有限的成形性给复杂部件的制造带来了巨大的挑战。本研究系统地探讨了透厚应力和成形温度对时效硬化2219铝合金成形性能的协同增强机制。开发了一个集全厚应力控制和温度调节于一体的平板拉伸测试平台，以评估不同热机械条件（75 ~ 225℃，0 ~ 180 MPa）下的极限成形高度（LFH）。与通常假设的单调关系相反，结果揭示了显著改善成形性的贯穿厚度应力（Pc）的临界阈值。PC随成形温度的升高而降低。低于Pc， LFH的改善可以忽略不计。当应力超过Pc时，LFH急剧增加。随着应力的继续增大，对LFH的增强作用逐渐减弱。显微组织分析表明，透厚应力通过抑制析出相的破碎和孔洞的生长，有效地减少了损伤的积累。当应力三轴性由正向负转变时，理论预测与实验结果吻合较好。在孔翻边应用中，120 MPa的全厚应力可使法兰高度提高17.4%，并将所需的成形温度降低25℃。这些发现不仅对贯穿厚度应力的非线性效应提供了基本见解，而且为时效硬化铝合金的有效成形提供了实用策略。

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引用次数: 0

Strengthening mechanism of IN 718 alloy fabricated by ultrasonic vibration-assisted laser directed energy deposition with heat treatment 超声振动辅助激光定向能沉积热处理in718合金的强化机理

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-14 DOI: 10.1016/j.jmapro.2026.01.003

Xiaoxia Qi , Yanle Li , Jiyu Du , Weiguang Fan , Yunjian Bai , Heng Chen , Fangyi Li

Continuous chain-like Laves phase is a significant factor leading to the failure of additively manufactured IN 718 alloy, resulting in the restricted application in critical aerospace components. To obtain high performance for IN 718 alloy, a novel processing strategy of laser directed energy deposition (LDED) combining bi-dimensional ultrasonic vibration (UV) and double aging (DA) is proposed to regulate Laves phase and γ″ phase. The DA-treated IN 718 sample with UV (UV-718A) achieves an ultimate tensile strength of 1389.7 ± 22.5 MPa and an elongation of 14.0 % ± 0.5 %, which are increased by 9.13 % and 33.3 %, respectively, compared to the DA-treated IN 718 without UV (NU-718A). Notably, the contributions of UV to yield strength before and after DA were 70.2 MPa and 113.7 MPa, respectively. The outstanding performance of the UV-718A sample was mainly attributed to refined grains and granular Laves phase surrounded by uniformly distributed γ′/γ″ phases. The finer grains and granular Laves phases result from the homogenization of alloy composition under UV, which promotes more uniform precipitation of γ″ phase (the distribution width expands by 80.4 %) during subsequent DA. Under the UV effect, the chain-like Laves phase is transformed into granular structures, and its content is reduced by 30.8 %, which contributes to improved ductility. Furthermore, fractographic analysis reveals that the failure mechanism for both the NU-718A and UV-718A samples is microvoids aggregation-induced fracture, where microvoids are caused by self-fragmentation of chain-like Laves phases and debonding of granular Laves phases. This research provides a processing strategy for high-performance critical aerospace components.

连续链状Laves相是导致增材制造的in718合金失效的重要因素，限制了其在航空航天关键部件上的应用。为了获得高性能的IN 718合金，提出了一种结合二维超声振动（UV）和双时效（DA）的激光定向能沉积（ld）工艺策略来调节Laves相和γ″相。经UV （UV- 718a）处理的IN 718试样的抗拉强度为1389.7±22.5 MPa，伸长率为14.0%±0.5%，分别比未经UV （NU-718A）处理的IN 718试样提高了9.13%和33.3%。值得注意的是，UV对DA前后屈服强度的贡献分别为70.2 MPa和113.7 MPa。UV-718A样品的优异性能主要归功于由均匀分布的γ′/γ″相包围的细化晶粒和粒状Laves相。在UV作用下，合金成分均质化，使得γ″相的析出更加均匀（分布宽度扩大了80.4%）。在UV作用下，条状Laves相转变为粒状组织，其含量降低了30.8%，有利于提高塑性。断口形貌分析表明，NU-718A和UV-718A试样的破坏机制均为微孔洞聚集断裂，微孔洞是由链状Laves相的自破碎和粒状Laves相的脱粘引起的。该研究为高性能航空航天关键部件的加工提供了一种策略。

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引用次数: 0

Internal pores in printed metal bumps: evolution mechanism and elimination strategy 印刷金属凸点内部孔隙：演化机制及消除策略

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-14 DOI: 10.1016/j.jmapro.2026.01.024

Lang Wu , Jun Luo , Yunlong Zhou , Yi Zhou , Shengnan Lv , Lehua Qi

Pore defects in metal droplet deposition, caused by gas entrainment, significantly degrade the reliability of printed bumps. While prior research has primarily addressed gas entrapment at the substrate interface leading to bottom pores, this study identifies a novel issue: droplet-top ambient gas entrainment causing internal pores within the bumps. To explore this phenomenon, we conducted bump printing experiments under varying substrate temperatures and impact velocities, inducing diverse gas-liquid interface behaviors. A three-dimensional numerical model, developed using the VOF method, analyzed the two-phase gas-liquid flow and solidification interface evolution within the droplet. Quantitative analysis, combining one-dimensional heat conduction and gas cavity collapse theories, revealed a strong link between internal pore formation and the thermodynamic coupling ratio of gas cavity retraction, λ_cav—defined as the ratio of gas cavity retraction timescale (τ_cav) to solidification timescale (τ_sol). Higher λ_cav values increase viscous shear forces, impeding gas cavity retraction and promoting solidification during slow retraction, thereby generating internal pore defects. To address this defect, we developed a “Thermal-Impact dual-field regulated printing” strategy, successfully printing a bump array free of internal pore defects on a chip. These findings enhance understanding of pore formation mechanisms in droplet-based additive manufacturing and provide practical elimination strategies, especially for flip-chip bonding applications.

金属液滴沉积中的孔隙缺陷是由气体夹带引起的，严重降低了印刷凸点的可靠性。虽然之前的研究主要是解决导致底部孔隙的基片界面气体夹带问题，但本研究发现了一个新问题：液滴顶部环境气体夹带导致凸起内部孔隙。为了探索这一现象，我们在不同的衬底温度和冲击速度下进行了凹凸印刷实验，诱导了不同的气液界面行为。利用VOF方法建立了三维数值模型，分析了液滴内部气液两相流动和凝固界面演化。结合一维热传导理论和空腔坍缩理论进行定量分析，揭示了内部孔隙形成与空腔收缩热力学耦合比（λcav）之间的密切联系，λcav定义为空腔收缩时间标度（τcav）与凝固时间标度（τsol）之比。λcav值越高，粘性剪切力越大，阻碍了气腔收缩，在缓慢收缩过程中促进了凝固，从而产生内部孔隙缺陷。为了解决这一缺陷，我们开发了一种“热冲击双场调节打印”策略，成功地在芯片上打印了一个没有内部孔缺陷的凹凸阵列。这些发现增强了对基于液滴的增材制造中孔隙形成机制的理解，并提供了实用的消除策略，特别是在倒装芯片键合应用中。

{"title":"Internal pores in printed metal bumps: evolution mechanism and elimination strategy","authors":"Lang Wu , Jun Luo , Yunlong Zhou , Yi Zhou , Shengnan Lv , Lehua Qi","doi":"10.1016/j.jmapro.2026.01.024","DOIUrl":"10.1016/j.jmapro.2026.01.024","url":null,"abstract":"<div><div>Pore defects in metal droplet deposition, caused by gas entrainment, significantly degrade the reliability of printed bumps. While prior research has primarily addressed gas entrapment at the substrate interface leading to bottom pores, this study identifies a novel issue: droplet-top ambient gas entrainment causing internal pores within the bumps. To explore this phenomenon, we conducted bump printing experiments under varying substrate temperatures and impact velocities, inducing diverse gas-liquid interface behaviors. A three-dimensional numerical model, developed using the VOF method, analyzed the two-phase gas-liquid flow and solidification interface evolution within the droplet. Quantitative analysis, combining one-dimensional heat conduction and gas cavity collapse theories, revealed a strong link between internal pore formation and the thermodynamic coupling ratio of gas cavity retraction, <em>λ</em><sub>cav</sub>—defined as the ratio of gas cavity retraction timescale (<em>τ</em><sub>cav</sub>) to solidification timescale (<em>τ</em><sub>sol</sub>). Higher <em>λ</em><sub>cav</sub> values increase viscous shear forces, impeding gas cavity retraction and promoting solidification during slow retraction, thereby generating internal pore defects. To address this defect, we developed a “Thermal-Impact dual-field regulated printing” strategy, successfully printing a bump array free of internal pore defects on a chip. These findings enhance understanding of pore formation mechanisms in droplet-based additive manufacturing and provide practical elimination strategies, especially for flip-chip bonding applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 150-165"},"PeriodicalIF":6.8,"publicationDate":"2026-01-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981209","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

Innovation in friction stir channeling technology towards dimensional optimization with a rectangularity of 93.0% 面向尺寸优化的搅拌摩擦通道技术创新，矩形度可达93.0%

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-14 DOI: 10.1016/j.jmapro.2026.01.025

Cheng Shan , Yuming Xie , Xiangchen Meng , Yilong Han , Shenglong Wang , Shengnan Hu , Ruitao Guo , Yongxian Huang

The manufacturing of high-performance cooling channels is critical for advancing thermal management systems in electric vehicles and aerospace. Conventional techniques, like milling and cover-plate welding, suffer from multi-step complexity, joint corrosion risks, and design constraints. Herein, friction stir channeling (FSC) is proposed as a transformative single-step solution for monolithic internal channel manufacturing. To address the long-standing challenge of channel shape irregularity, a novel material overflow-reflux model and a tip-enlarged tool are developed, with formation mechanisms elucidated through combined numerical modeling and experimental validation. The optimized process achieves large-scale channels (10 mm width, 2 mm height) with an unprecedentedly high rectangularity of 93.0%. These monolithic channels demonstrate exceptional performance, sustaining leak-free operation under 1 MPa for 7200 s and achieving a high heat dissipation rate of 16 K/s. This work advances FSC as a robust and promising approach for creating highly efficient, reliable, and integrated cooling components, providing fundamental insights for its application in advanced thermal management systems.

高性能冷却通道的制造对于推进电动汽车和航空航天领域的热管理系统至关重要。传统的工艺，如铣削和盖板焊接，存在多步骤复杂性、接头腐蚀风险和设计限制。本文提出了搅拌摩擦通道（FSC）作为单片内部通道制造的变革性单步解决方案。为了解决河道形状不规则这一长期存在的挑战，研究人员开发了一种新的物质溢出回流模型和一种尖端放大工具，并通过数值模拟和实验验证相结合来阐明形成机制。优化后的工艺实现了大尺寸通道（宽10 mm，高2 mm），矩形度达到了前所未有的93.0%。这些单片通道表现出卓越的性能，在1mpa下保持7200秒无泄漏工作，并实现16 K/s的高散热率。这项工作推进了FSC作为一种强大而有前途的方法，用于创建高效，可靠和集成的冷却组件，为其在先进热管理系统中的应用提供了基本见解。

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引用次数: 0

Real-time burr monitoring in CFRP micro-drilling using a PVDF-based AE sensor and CNN-assisted signal classification 基于pvdf声发射传感器和cnn辅助信号分类的CFRP微孔毛刺实时监测

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-14 DOI: 10.1016/j.jmapro.2026.01.023

Hyo-jeong Kim , Seoung-hwan Lee

This study presents a real-time acoustic emission (AE)-based monitoring framework for burr formation in the micro-drilling of carbon fiber reinforced plastics (CFRP). A polyvinylidene fluoride (PVDF)-based sensor is employed as a low-cost, flexible alternative to conventional AE sensors and is calibrated to ISO standards to ensure high-frequency signal fidelity. AE signals collected during drilling are analyzed using continuous wavelet transform (CWT) to capture the signal characteristics associated with fiber fracture and delamination. A convolutional neural network (CNN) is trained on time-frequency scalograms to classify machining parameters with high accuracy. Experimental validation shows that drill diameter is the most significant factor affecting burr formation, as confirmed by two-way ANOVA. The proposed PVDF-CWT-CNN framework successfully identifies process conditions in real-time and offers a scalable approach for intelligent monitoring in high-precision CFRP machining.

本研究提出了一种基于声发射（AE）的碳纤维增强塑料（CFRP）微钻孔毛刺形成实时监测框架。基于聚偏氟乙烯（PVDF）的传感器是传统声发射传感器的一种低成本、灵活的替代品，并根据ISO标准进行校准，以确保高频信号的保真度。利用连续小波变换（CWT）对钻井过程中收集的声发射信号进行分析，以捕获与纤维断裂和分层相关的信号特征。利用时频尺度图训练卷积神经网络（CNN）对加工参数进行高精度分类。实验验证表明，钻头直径是影响毛刺形成的最显著因素，双向方差分析证实了这一点。提出的PVDF-CWT-CNN框架成功地实时识别工艺条件，并为高精度CFRP加工的智能监控提供了一种可扩展的方法。

引用次数: 0

Laser cladding process optimization via multimodal generative prediction and reinforcement learning 基于多模态生成预测和强化学习的激光熔覆工艺优化

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-13 DOI: 10.1016/j.jmapro.2026.01.004

Yixuan Dong , Tonghui Wang , Chuang Guan , Yiqi Wang , Jinsu Yu , Tianbiao Yu

Laser cladding (LC) is widely used for high-performance surface enhancement and component repair, with its processing quality highly dependent on complex parameter configurations. However, for LC-applied high-entropy alloy (HEA) coatings, the high cost of sample acquisition and the limitations of traditional response surface methods make it difficult to achieve accurate optimization under small-sample scenarios. This study proposes a laser cladding process parameter optimization method for MoNbTaTiZr powder, integrating multimodal surrogate modeling with reinforcement learning. A conditional generative adversarial network (cGAN) is employed to generate cross-sectional feature images of the cladding layer, which are further processed using a convolutional neural network (CNN) combined with a multi-task architecture to jointly predict multiple performance metrics, including dilution rate, shape factor, and microhardness. Based on this framework, this study proposes a Soft Actor-Critic algorithm with perturbation-aware replay optimization (PRO-SAC) method, which incorporates policy perturbation sensitivity, Temporal Difference (TD) error, and Pareto-front information of samples to jointly drive experience replay, thereby improving the learning efficiency and stability of process parameter optimization strategies. Experimental results show that the proposed prediction model achieves correlation coefficients above 0.97 for all quality indicators. Compared with other classical methods, the PRO-SAC optimization results exhibit superior performance across multiple evaluation metrics. Under the constraint of maintaining the shape factor, the microhardness and dilution rate of the cladding layer are improved by 11.3 % and 0.24 %, respectively, relative to the best values in the existing training dataset, confirming the effectiveness and engineering adaptability of the proposed method for laser cladding parameter optimization.

激光熔覆（LC）广泛应用于高性能表面增强和部件修复，其加工质量高度依赖于复杂的参数配置。然而，对于lc应用的高熵合金（HEA）涂层，由于样品采集成本高和传统响应面方法的局限性，难以在小样本情况下实现精确的优化。本研究提出了一种将多模态代理建模与强化学习相结合的MoNbTaTiZr粉末激光熔覆工艺参数优化方法。采用条件生成对抗网络（conditional generative adversarial network, cGAN）生成熔覆层的截面特征图像，并使用卷积神经网络（convolutional neural network， CNN）结合多任务架构对其进行进一步处理，共同预测包括稀释率、形状因子和显微硬度在内的多个性能指标。基于此框架，本文提出了一种带有扰动感知重播优化（PRO-SAC）方法的软Actor-Critic算法，该算法将策略扰动敏感性、时间差（TD）误差和样本的Pareto-front信息结合起来共同驱动经验重播，从而提高了过程参数优化策略的学习效率和稳定性。实验结果表明，所提出的预测模型各质量指标的相关系数均在0.97以上。与其他经典方法相比，PRO-SAC优化结果在多个评价指标上表现出优越的性能。在保持形状因子的约束下，熔覆层的显微硬度和稀释率相对于现有训练数据集中的最佳值分别提高了11.3%和0.24%，验证了所提方法用于激光熔覆参数优化的有效性和工程适应性。

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引用次数: 0

An online chatter detection for milling based on a novel convolutional neural network and small probability hypothesis method 基于卷积神经网络和小概率假设方法的铣削颤振在线检测

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-13 DOI: 10.1016/j.jmapro.2026.01.012

Yongliang Lu , Jun Zhao , Anhai Li , Xujie Tang , Junfu Liu

Milling chatter can seriously reduce the surface quality and production efficiency of the workpiece being machined, so accurate chatter detection is essential. In recent years, convolutional neural networks (CNNs) have been extensively employed for chatter detection, demonstrating promising effectiveness. However, the quality of data labeling and the training process substantially affect the generalization and accuracy of CNNs. To overcome the above limitations, this paper proposed a novel hybrid deep convolutional neural network (HDCNN) named Chatter-CNN for online chatter detection in milling processes. The model integrates an Inception-Chatter module and a Squeeze-and-Excitation Residual Mutual Information (SR-MI) block, utilizing both milling force and vibration acceleration signals during datasets construction. Furthermore, an early chatter detection method based on the small-probability hypothesis combined with cumulative sum (CUSUM) is developed. Comparative milling experiments are conducted on a wedge-shaped workpiece and a thin-walled workpiece under different cutting parameters, cutting edges and tool overhang lengths to verify the detection performance of the proposed Chatter-CNN. Experimental results demonstrate that the proposed Chatter-CNN achieves 99.9 % / 94.7 % (validation/test) on the wedge-shaped workpiece and 99.8 % / 94.2 % (validation/test) on the thin-walled workpiece, outperforming existing CNNs. Further experimental results combining the proposed early detection method show that Chatter-CNN outperforms existing CNNs and threshold-based techniques by more accurately identifying machining states, including transition states, and enabling earlier detection of chatter onset, thereby facilitating chatter suppression.

铣削颤振会严重降低被加工工件的表面质量和生产效率，因此精确的颤振检测至关重要。近年来，卷积神经网络（cnn）被广泛应用于颤振检测，显示出良好的效果。然而，数据标注和训练过程的质量极大地影响了cnn的泛化和准确性。为了克服上述局限性，本文提出了一种新的混合深度卷积神经网络（HDCNN），命名为chatter - cnn，用于铣削过程中的在线颤振检测。该模型集成了一个启动-颤振模块和一个挤压-激励剩余互信息（SR-MI）模块，在数据集构建过程中同时利用铣削力和振动加速度信号。在此基础上，提出了一种基于小概率假设与累积和相结合的早期颤振检测方法。通过对楔形工件和薄壁工件在不同切削参数、切削刃和刀具悬垂长度下的铣削对比实验，验证了该方法的检测性能。实验结果表明，所提出的Chatter-CNN在楔形工件上达到99.9% / 94.7%（验证/测试），在薄壁工件上达到99.8% / 94.2%（验证/测试），优于现有的cnn。结合提出的早期检测方法，进一步的实验结果表明，通过更准确地识别加工状态，包括过渡状态，更早地检测颤振的发生，从而有利于颤振抑制，chatter - cnn优于现有的cnn和基于阈值的技术。

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引用次数: 0

Multi-physics investigation on the influence of impurity elements and scanning parameters on the surface topography in laser powder bed fusion 杂质元素和扫描参数对激光粉末床熔合表面形貌影响的多物理场研究

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-13 DOI: 10.1016/j.jmapro.2026.01.011

Xingyue Zhai , Ziad Moumni , Zhidong Zhang , Feifan Li , Shuheng Wang , Xiaojun Gu , Jihong Zhu , Weihong Zhang

Surface topography critically governs the mechanical performance—particularly fatigue resistance-of components fabricated via laser powder bed fusion (LPBF). To advance the understanding of how parameters govern surface formation, a comprehensive multi-physics model was developed, integrating random powder deposition (Discrete Element Method), laser-material interaction and melt pool (MP) dynamics (Finite Volume Method). The framework integrates surface-active elements with a strongly coupled laser tracing model, leading to two critical advances: first, it provides new insights into the role of surface-active elements in MP dynamics; second, it successfully reproduces, the complex formation mechanisms of varying surface topography in multi-track scans by constant surface-active elements: 1) impurity effects: explicitly modeling sulfur and oxygen interactions within the MP, and reveal these elements substantially degrade surface quality through complex thermo-physics mechanisms. Quantitative analysis reveals sulfur exerts a 2.74× stronger influence on surface peak formation than oxygen when concentrations decrease tenfold (S: 0.3 → 0.03%; O: 0.1 → 0.01%), establishing its dominance in surface topography evolution. However, at ultralow oxygen‑sulfur concentrations, surface topography converges to identical configurations. 2) scanning parameter effects: a coupled analysis of scanning parameter effects-encompassing strategy, speed, and hatch spacing-on non-uniform temperature field evolution is conducted, evaluating-i): energy absorptivity dynamics, ii) surface-induced porosity, iii) inter-track interaction mechanisms, iv) Plateau-Rayleigh instabilities and v) interaction of melt rate, melt flow velocity, inertia and surface tension on surface topography. This study reveals that localized peaks within the MP disrupt laser beam reflection, altering MP dynamics. Furthermore, irregular surface peaks and valleys contribute to the formation of various surface pore types. Critically, during multi-track process, the coupling between scanning strategy and speed generates heterogeneous thermal fields that significantly alter subsequent surface evolution. Our paper provides theoretical guides to help users of additive manufacturing optimize the topography of parts.

表面形貌对激光粉末床熔合（LPBF）制造的部件的机械性能，特别是抗疲劳性能起着至关重要的作用。为了促进对参数如何影响表面形成的理解，开发了一个综合的多物理场模型，集成了随机粉末沉积（离散元法）、激光-材料相互作用和熔池（MP）动力学（有限体积法）。该框架将表面活性元素与强耦合激光示踪模型集成在一起，导致两个关键进展：首先，它为表面活性元素在MP动力学中的作用提供了新的见解；其次，它通过恒定的表面活性元素成功地再现了多径扫描中不同表面形貌的复杂形成机制：1)杂质效应：明确地模拟了MP内硫和氧的相互作用，并揭示了这些元素通过复杂的热物理机制大大降低了表面质量。定量分析表明，当硫浓度降低10倍时（S: 0.3→0.03%;O: 0.1→0.01%），硫对表面峰形成的影响是氧的2.74倍，在表面形貌演化中占主导地位。然而，在超低氧硫浓度下，表面形貌收敛到相同的构型。2)扫描参数效应：对扫描参数对非均匀温度场演化的影响进行了耦合分析，评估了i)：能量吸收动力学，ii)表面诱导孔隙率，iii)轨道间相互作用机制，iv)高原-瑞利不稳定性，v)熔化速率、熔体流动速度、惯性和表面张力对表面形貌的相互作用。该研究表明，在mps内的局部峰破坏了激光束的反射，改变了mps动力学。此外，不规则的表面峰谷有助于形成各种表面孔隙类型。关键是，在多道过程中，扫描策略和速度之间的耦合产生了非均匀热场，显著改变了随后的表面演变。本文为增材制造用户优化零件形貌提供了理论指导。

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