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A novel reluctance electromagnetic riveting process: Multi-field coupling numerical and experimental studies
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.068
Qi Hu , Zengqiang Cao , Minghao Zhang , Junhuan Wang , Xinglong Gong , Yingjiang Guo , Lubin Huo
This study proposes a novel reluctance electromagnetic riveting (REMR) process based on the magnetization of a ferromagnetic projectile, aimed at addressing the low energy conversion efficiency of traditional induction electromagnetic riveting (IEMR). A multi-field coupled electromagnetic-dynamic-mechanical finite element model was established, and an REMR experimental device was constructed. The driven head dimensions obtained from simulations and experiments matched well, with an error margin of within 6.3 %. By combining numerical simulations with comparative experiments against IEMR, the effects of seven key process parameters on REMR energy conversion efficiency was analyzed. The results revealed that REMR exhibits higher energy conversion efficiency, riveting force, and strain rate at lower voltages. For riveting Φ5 mm 2A10 aluminum alloy rivets to similar driven head dimensions, the voltage required by REMR was 145 V lower than that of IEMR, resulting in a 156 % increase in energy conversion efficiency. Furthermore, microstructural observation showed that REMR rivets undergo plastic deformation through an adiabatic shear mechanism, forming adiabatic shear bands (ASBs). The ASBs formed by REMR are narrower and exhibit more severe grain deformation compared to those formed by IEMR due to the increased strain rate.
{"title":"A novel reluctance electromagnetic riveting process: Multi-field coupling numerical and experimental studies","authors":"Qi Hu ,&nbsp;Zengqiang Cao ,&nbsp;Minghao Zhang ,&nbsp;Junhuan Wang ,&nbsp;Xinglong Gong ,&nbsp;Yingjiang Guo ,&nbsp;Lubin Huo","doi":"10.1016/j.jmapro.2024.12.068","DOIUrl":"10.1016/j.jmapro.2024.12.068","url":null,"abstract":"<div><div>This study proposes a novel reluctance electromagnetic riveting (REMR) process based on the magnetization of a ferromagnetic projectile, aimed at addressing the low energy conversion efficiency of traditional induction electromagnetic riveting (IEMR). A multi-field coupled electromagnetic-dynamic-mechanical finite element model was established, and an REMR experimental device was constructed. The driven head dimensions obtained from simulations and experiments matched well, with an error margin of within 6.3 %. By combining numerical simulations with comparative experiments against IEMR, the effects of seven key process parameters on REMR energy conversion efficiency was analyzed. The results revealed that REMR exhibits higher energy conversion efficiency, riveting force, and strain rate at lower voltages. For riveting Φ5 mm 2A10 aluminum alloy rivets to similar driven head dimensions, the voltage required by REMR was 145 V lower than that of IEMR, resulting in a 156 % increase in energy conversion efficiency. Furthermore, microstructural observation showed that REMR rivets undergo plastic deformation through an adiabatic shear mechanism, forming adiabatic shear bands (ASBs). The ASBs formed by REMR are narrower and exhibit more severe grain deformation compared to those formed by IEMR due to the increased strain rate.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 207-220"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132267","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
Thermodynamic quantitative analysis and formation mechanism on novel multilayered Fe-Si core-shell magnetic abrasives
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.042
Guodong Liang , Bo Cheng , Xinjian Zhang , Yu Zhao , Xudong Zhao , Boru Jin , Wensheng Li
Based on the direct combination of traditional abrasive hard phase particles and ferromagnetic phase matrix, this study introduces a multilayer self-sharpening structure aimed at improving the durability of abrasives. The effects of holding temperature and holding time on the microstructure of the gradient grinding layer on the surface of ferromagnetic phase during the pack cementation process are analyzed. The phase transition mechanism of the abrasive layer, transitioning from a bilayer structure in the pre-insulation phase to a trilayer structure in the post-insulation phase explained by diffusion thermodynamics. A model is established between the diffusion driving force (F) and the thickness (H) of each layer in the gradient coating through ∆G. Finally, the finishing performance and durability of the new abrasive is tested. The results show that the microstructure of abrasive formed at 725 °C for 3 h, consisting of 3 μm FeSi2 outer layer, 14 μm FeSi intermediate layer and 5 μm Fe3Si inner layer, exhibits uniform and dense structure, without obvious cracking and spalling at the coating-substrate interface, and forms a strong metallurgical bonding interface. Quantitative calculations from the diffusion model show that the diffusion driving force is directly related to the thickness of each layer within the gradient diffusion layer. The greater the driving force of the compound, the greater the thickness. The surface roughness (Ra) of the zirconium tube decreases from 0.2008 μm to 0.1170 μm after 3 passes of finishing. The gradient self-sharpening structure of the new abrasive makes its finishing life reach 150 min, demonstrating excellent durability.
{"title":"Thermodynamic quantitative analysis and formation mechanism on novel multilayered Fe-Si core-shell magnetic abrasives","authors":"Guodong Liang ,&nbsp;Bo Cheng ,&nbsp;Xinjian Zhang ,&nbsp;Yu Zhao ,&nbsp;Xudong Zhao ,&nbsp;Boru Jin ,&nbsp;Wensheng Li","doi":"10.1016/j.jmapro.2024.12.042","DOIUrl":"10.1016/j.jmapro.2024.12.042","url":null,"abstract":"<div><div>Based on the direct combination of traditional abrasive hard phase particles and ferromagnetic phase matrix, this study introduces a multilayer self-sharpening structure aimed at improving the durability of abrasives. The effects of holding temperature and holding time on the microstructure of the gradient grinding layer on the surface of ferromagnetic phase during the pack cementation process are analyzed. The phase transition mechanism of the abrasive layer, transitioning from a bilayer structure in the pre-insulation phase to a trilayer structure in the post-insulation phase explained by diffusion thermodynamics. A model is established between the diffusion driving force (F) and the thickness (H) of each layer in the gradient coating through ∆G. Finally, the finishing performance and durability of the new abrasive is tested. The results show that the microstructure of abrasive formed at 725 °C for 3 h, consisting of 3 μm FeSi<sub>2</sub> outer layer, 14 μm FeSi intermediate layer and 5 μm Fe<sub>3</sub>Si inner layer, exhibits uniform and dense structure, without obvious cracking and spalling at the coating-substrate interface, and forms a strong metallurgical bonding interface. Quantitative calculations from the diffusion model show that the diffusion driving force is directly related to the thickness of each layer within the gradient diffusion layer. The greater the driving force of the compound, the greater the thickness. The surface roughness (Ra) of the zirconium tube decreases from 0.2008 μm to 0.1170 μm after 3 passes of finishing. The gradient self-sharpening structure of the new abrasive makes its finishing life reach 150 min, demonstrating excellent durability.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 158-174"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132270","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
Microscale investigation of molten pool flow and microstructure evolution of Inconel718 alloy during solid-liquid transition
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.046
Kaikai Xu , Yadong Gong , Qiang Zhao , Guiru Meng , Meng Zhao
In Laser Direct Energy Deposition (L-DED), the heat and mass transfer within the molten pool significantly impact the evolution of dendritic structures and the surface characteristics of the deposited components. To advance the study of the solid-liquid transition, a numerical model that simulates molten pool flow and solidification is essential. Parameters derived from solidification are integrated with the phase field model to simulate dendrite growth during the solid-liquid transition. Furthermore, to validate the coherence between numerical simulations and experimental observations, numerous single-track samples were produced using L-DED. It is anticipated that the flow direction of the molten pool will be influenced by heat convection and powder disturbances. As the laser moves and heats the material, the volume of the melt pool increases gradually, and the pool's shape remains symmetric along the direction of motion. The temperature gradient has a significant impact on the dendrite tip growth rate. During nucleation, dendrites develop in an ultra-cold solution. Dendritic competition and growth interact, leading to variations in dendritic size and growth rates. Due to insufficient solute diffusion within the dendrite, the solute concentration in the dendrite remains elevated.
{"title":"Microscale investigation of molten pool flow and microstructure evolution of Inconel718 alloy during solid-liquid transition","authors":"Kaikai Xu ,&nbsp;Yadong Gong ,&nbsp;Qiang Zhao ,&nbsp;Guiru Meng ,&nbsp;Meng Zhao","doi":"10.1016/j.jmapro.2024.12.046","DOIUrl":"10.1016/j.jmapro.2024.12.046","url":null,"abstract":"<div><div>In Laser Direct Energy Deposition (L-DED), the heat and mass transfer within the molten pool significantly impact the evolution of dendritic structures and the surface characteristics of the deposited components. To advance the study of the solid-liquid transition, a numerical model that simulates molten pool flow and solidification is essential. Parameters derived from solidification are integrated with the phase field model to simulate dendrite growth during the solid-liquid transition. Furthermore, to validate the coherence between numerical simulations and experimental observations, numerous single-track samples were produced using L-DED. It is anticipated that the flow direction of the molten pool will be influenced by heat convection and powder disturbances. As the laser moves and heats the material, the volume of the melt pool increases gradually, and the pool's shape remains symmetric along the direction of motion. The temperature gradient has a significant impact on the dendrite tip growth rate. During nucleation, dendrites develop in an ultra-cold solution. Dendritic competition and growth interact, leading to variations in dendritic size and growth rates. Due to insufficient solute diffusion within the dendrite, the solute concentration in the dendrite remains elevated.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 482-493"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131696","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
Material removal profile model simulations and experiments on the non-contact shear thickening polishing of K9 glass
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.055
Jun Zhao , Wenbing Wang , Xianwei Qiu , Zixuan Wang , Cheng Fan
To achieve the precise prediction and control of material removal profiles and workpiece surface shapes during shear thickening polishing, this paper introduces the non-contact shear thickening polishing (NCSTP) method. This method comprehensively considers processing parameters such as tool movement angle, tool rotation, machining gap, and flow field characteristics based on the NCSTP process. A theoretical model framework for NCSTP material removal profiles is established that integrates shear thickening fluid simulation and microscopic abrasive material removal mechanisms. This framework enables the accurate prediction of material removal profiles during both fixed-point machining and precession processing along a straight line, thereby revealing the NCSTP material removal mechanism. Experimental results from polishing optical K9 glass demonstrate highly consistent material removal profiles between the experimental and theoretical outcomes, with a maximum average error of 4.45 %. Furthermore, verification of the NCSTP model through linear precession polishing experiments on K9 optical glass show significant surface roughness improvement. Specifically, the surface roughness Ra decreases from 465.77 nm to 41.55 nm after single-feed polishing, resulting in a surface roughness improvement rate of 91.1 %. Additionally, numerical simulations of the NCSTP process reveal intermediate process parameters that are challenging to obtain directly through experiments, including the distributions of hydrodynamic pressure, shear stress, and abrasive particle velocity within the polishing fluid. These insights quantitatively elucidate the influence on the polishing material removal profile, thereby enhancing understanding of the material removal mechanism during NCSTP.
{"title":"Material removal profile model simulations and experiments on the non-contact shear thickening polishing of K9 glass","authors":"Jun Zhao ,&nbsp;Wenbing Wang ,&nbsp;Xianwei Qiu ,&nbsp;Zixuan Wang ,&nbsp;Cheng Fan","doi":"10.1016/j.jmapro.2024.12.055","DOIUrl":"10.1016/j.jmapro.2024.12.055","url":null,"abstract":"<div><div>To achieve the precise prediction and control of material removal profiles and workpiece surface shapes during shear thickening polishing, this paper introduces the non-contact shear thickening polishing (NCSTP) method. This method comprehensively considers processing parameters such as tool movement angle, tool rotation, machining gap, and flow field characteristics based on the NCSTP process. A theoretical model framework for NCSTP material removal profiles is established that integrates shear thickening fluid simulation and microscopic abrasive material removal mechanisms. This framework enables the accurate prediction of material removal profiles during both fixed-point machining and precession processing along a straight line, thereby revealing the NCSTP material removal mechanism. Experimental results from polishing optical K9 glass demonstrate highly consistent material removal profiles between the experimental and theoretical outcomes, with a maximum average error of 4.45 %. Furthermore, verification of the NCSTP model through linear precession polishing experiments on K9 optical glass show significant surface roughness improvement. Specifically, the surface roughness Ra decreases from 465.77 nm to 41.55 nm after single-feed polishing, resulting in a surface roughness improvement rate of 91.1 %. Additionally, numerical simulations of the NCSTP process reveal intermediate process parameters that are challenging to obtain directly through experiments, including the distributions of hydrodynamic pressure, shear stress, and abrasive particle velocity within the polishing fluid. These insights quantitatively elucidate the influence on the polishing material removal profile, thereby enhancing understanding of the material removal mechanism during NCSTP.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 435-451"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131703","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
A mechanism and data fusion step-wise prediction framework for hot-rolled strip thickness
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.073
Yu Wen, Yafeng Ji, Borun Wu, Weijian Wang
In the hot-rolled process, the accurate hitting of strip thickness is key to production quality control. In this paper, a novel fusion strategy is proposed to address the problem that traditional thickness mechanism (TM) models and machine learning (ML) models have their own advantages and problems. A step-wise prediction framework for the fusion of mechanism and data is built by introducing the production requirements of enterprises. The construction of the framework begins with parsing the rolling mechanism and analyzing the data influence law. In order to ensure the model accuracy, the methods of model self-learning and feature engineering are individually introduced to construct TM and ML models, and they are stored in the model library. Subsequently, a kind of performance evaluation rule base is developed, based on practical applications in the industrial field. According to the order of importance of the accuracy, stability and timeliness indicators of the enterprise production requirement scheduling model, a step-wise prediction model (MCT) of ML compensation correction TM is established. In addition, considering the “black box” characteristic of ML, eXplainable Artificial Intelligence (XAI), especially the SHapley Additive exPlanations (SHAP) method, is adopted to explain the prediction results of ML. Through the influence mechanism of transparent process parameters on strip thickness deviation, the key parameters are identified and the subsequent decision deployment is optimized. At the same time, the reasons for the appearance of anomalous prediction points of the model are diagnosed, and the improvement means are proposed by combining the rolling process mechanism and ML modeling. The experimental results show that compared with other traditional methods, the framework can better meet the production quality requirements and can provide a reference for practical industrial applications.
{"title":"A mechanism and data fusion step-wise prediction framework for hot-rolled strip thickness","authors":"Yu Wen,&nbsp;Yafeng Ji,&nbsp;Borun Wu,&nbsp;Weijian Wang","doi":"10.1016/j.jmapro.2024.12.073","DOIUrl":"10.1016/j.jmapro.2024.12.073","url":null,"abstract":"<div><div>In the hot-rolled process, the accurate hitting of strip thickness is key to production quality control. In this paper, a novel fusion strategy is proposed to address the problem that traditional thickness mechanism (TM) models and machine learning (ML) models have their own advantages and problems. A step-wise prediction framework for the fusion of mechanism and data is built by introducing the production requirements of enterprises. The construction of the framework begins with parsing the rolling mechanism and analyzing the data influence law. In order to ensure the model accuracy, the methods of model self-learning and feature engineering are individually introduced to construct TM and ML models, and they are stored in the model library. Subsequently, a kind of performance evaluation rule base is developed, based on practical applications in the industrial field. According to the order of importance of the accuracy, stability and timeliness indicators of the enterprise production requirement scheduling model, a step-wise prediction model (MCT) of ML compensation correction TM is established. In addition, considering the “black box” characteristic of ML, eXplainable Artificial Intelligence (XAI), especially the SHapley Additive exPlanations (SHAP) method, is adopted to explain the prediction results of ML. Through the influence mechanism of transparent process parameters on strip thickness deviation, the key parameters are identified and the subsequent decision deployment is optimized. At the same time, the reasons for the appearance of anomalous prediction points of the model are diagnosed, and the improvement means are proposed by combining the rolling process mechanism and ML modeling. The experimental results show that compared with other traditional methods, the framework can better meet the production quality requirements and can provide a reference for practical industrial applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 680-696"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131934","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
Numerical simulations of molten pool dynamics in wire-arc directed energy deposition processes: A review
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2025.01.022
Hao Yi , Furui Jiao , Huajun Cao , Jiahui Zhang , Yu Zou
Wire-arc direct energy deposition (DED) technology has proven to offer irreplaceable advantages in the production of complex, large, and ultra-large components, owing to its distinctive characteristics, including cost-effectiveness, rapid processing speeds, and freedom from dimensional constraints. In practical applications, the molten pool dynamics exerts a decisive influence on the quality of the final components, a factor that cannot be overlooked. Solely relying on experiments is difficult to quantitatively and scientifically comprehending the physical mechanisms associated with the deposition process. In contrast, numerical simulation technology has a unique advantage in understanding the scientific nature, perfecting the theoretical framework, and guiding the experiments. To this end, this paper systematically reviews the numerical simulation studies of the wire-arc DED, focusing on molten pool dynamics. Firstly, the physical model and some approximations in the model establishment process are introduced. In addition, the molten pool dynamics under different deposition strategies and in-situ assistance of multi-energy fields are analysed in depth, mainly covering the transient evolution and physical mechanisms of the molten pool. Finally, the future development trends in numerical simulation of molten pool dynamics are predicted, providing valuable insights for enhancing the theoretical framework of wire-arc DED technology.
{"title":"Numerical simulations of molten pool dynamics in wire-arc directed energy deposition processes: A review","authors":"Hao Yi ,&nbsp;Furui Jiao ,&nbsp;Huajun Cao ,&nbsp;Jiahui Zhang ,&nbsp;Yu Zou","doi":"10.1016/j.jmapro.2025.01.022","DOIUrl":"10.1016/j.jmapro.2025.01.022","url":null,"abstract":"<div><div>Wire-arc direct energy deposition (DED) technology has proven to offer irreplaceable advantages in the production of complex, large, and ultra-large components, owing to its distinctive characteristics, including cost-effectiveness, rapid processing speeds, and freedom from dimensional constraints. In practical applications, the molten pool dynamics exerts a decisive influence on the quality of the final components, a factor that cannot be overlooked. Solely relying on experiments is difficult to quantitatively and scientifically comprehending the physical mechanisms associated with the deposition process. In contrast, numerical simulation technology has a unique advantage in understanding the scientific nature, perfecting the theoretical framework, and guiding the experiments. To this end, this paper systematically reviews the numerical simulation studies of the wire-arc DED, focusing on molten pool dynamics. Firstly, the physical model and some approximations in the model establishment process are introduced. In addition, the molten pool dynamics under different deposition strategies and in-situ assistance of multi-energy fields are analysed in depth, mainly covering the transient evolution and physical mechanisms of the molten pool. Finally, the future development trends in numerical simulation of molten pool dynamics are predicted, providing valuable insights for enhancing the theoretical framework of wire-arc DED technology.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 970-997"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132049","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
Expanding the applicability of material jetting–printed photopolymer prototype injection moulds by gamma irradiation post-treatment
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.037
Szabolcs Krizsma , László Mészáros , Norbert Krisztián Kovács , András Suplicz
Additive manufacturing (AM) revolutionized modern production and tooling, as it can help speed up the development process. This is also true for injection moulding. For instance, polymeric low-volume injection moulds are easy to produce by material jetting (MJ) technologies like PolyJet™. The downside of these MJ printed moulds is their relatively low glass transition temperature, which can result in unacceptably low stiffness and increased creep compliance in the operational temperature range. Different post-curing techniques like high-energy irradiation can enhance the degree of cross-linking in MJ-printed photopolymer parts. We applied MJ (PolyJet™ technology) to produce specimens for mechanical and morphological characterizations and low-volume injection moulds. After printing, we subjected the specimens and the inserts to high-energy gamma irradiation with doses of 50 kGy, 100 kGy, 150 kGy and 200 kGy. Dynamic mechanical analysis (DMA) showed the effects of irradiation on material properties: the glass transition temperature of the photopolymer rose by almost 10 °C from 70.8 °C of the untreated insert to 81.6 °C of the specimen irradiated with 200 kGy. The creep time temperature superposition (TTS) tests proved that the increasing irradiation doses significantly reduced creep compliance, which resulted in considerably lower mould insert deformations. Creep compliance measured at 35 °C fell from 1920 μm2/N of the untreated specimen to 518 μm2/N of the specimen irradiated with 200 kGy. After the material tests, we applied an elaborated comprehensive state monitoring system (operational strain, cavity pressure and temperature measurements) to highlight the fundamental effect that the irradiation has on the operational behaviour of the MJ-printed mould inserts. Injection moulding tests showed that the increasing irradiation doses resulted in significantly decreased operational deformations. Maximal operational strain of the mould inserts fell from 1 % measured on the untreated (0 kGy) insert to 0.5 % measured on the insert irradiated with 200 kGy. It is highly desirable because product dimensional accuracy is also increased. Irradiation also significantly increased mould life (the number of products that can be manufactured), which is a crucial advantage from an economic point of view. We proved that post-curing by gamma radiation is a feasible way to enhance the applicability and the dimensional stability of photopolymer injection mould inserts. This is a definitely novel way to enhance the applicability of MJ-printed low-volume injection moulds.
{"title":"Expanding the applicability of material jetting–printed photopolymer prototype injection moulds by gamma irradiation post-treatment","authors":"Szabolcs Krizsma ,&nbsp;László Mészáros ,&nbsp;Norbert Krisztián Kovács ,&nbsp;András Suplicz","doi":"10.1016/j.jmapro.2024.12.037","DOIUrl":"10.1016/j.jmapro.2024.12.037","url":null,"abstract":"<div><div>Additive manufacturing (AM) revolutionized modern production and tooling, as it can help speed up the development process. This is also true for injection moulding. For instance, polymeric low-volume injection moulds are easy to produce by material jetting (MJ) technologies like PolyJet™. The downside of these MJ printed moulds is their relatively low glass transition temperature, which can result in unacceptably low stiffness and increased creep compliance in the operational temperature range. Different post-curing techniques like high-energy irradiation can enhance the degree of cross-linking in MJ-printed photopolymer parts. We applied MJ (PolyJet™ technology) to produce specimens for mechanical and morphological characterizations and low-volume injection moulds. After printing, we subjected the specimens and the inserts to high-energy gamma irradiation with doses of 50 kGy, 100 kGy, 150 kGy and 200 kGy. Dynamic mechanical analysis (DMA) showed the effects of irradiation on material properties: the glass transition temperature of the photopolymer rose by almost 10 °C from 70.8 °C of the untreated insert to 81.6 °C of the specimen irradiated with 200 kGy. The creep time temperature superposition (TTS) tests proved that the increasing irradiation doses significantly reduced creep compliance, which resulted in considerably lower mould insert deformations. Creep compliance measured at 35 °C fell from 1920 μm<sup>2</sup>/N of the untreated specimen to 518 μm<sup>2</sup>/N of the specimen irradiated with 200 kGy. After the material tests, we applied an elaborated comprehensive state monitoring system (operational strain, cavity pressure and temperature measurements) to highlight the fundamental effect that the irradiation has on the operational behaviour of the MJ-printed mould inserts. Injection moulding tests showed that the increasing irradiation doses resulted in significantly decreased operational deformations. Maximal operational strain of the mould inserts fell from 1 % measured on the untreated (0 kGy) insert to 0.5 % measured on the insert irradiated with 200 kGy. It is highly desirable because product dimensional accuracy is also increased. Irradiation also significantly increased mould life (the number of products that can be manufactured), which is a crucial advantage from an economic point of view. We proved that post-curing by gamma radiation is a feasible way to enhance the applicability and the dimensional stability of photopolymer injection mould inserts. This is a definitely novel way to enhance the applicability of MJ-printed low-volume injection moulds.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 135-145"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132271","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}
引用次数: 0
Atomic surface of titanium alloy using novel chemical mechanical polishing with rare earth composite abrasives
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.036
Huiguang Sun , Zhenyu Zhang , Zihang Xue , Hongxiu Zhou , Zaiming Geng , Chuanshi Cheng , Leilei Chen , Ye Tian
Titanium (Ti) alloy is a typical difficult-to-process material, rising a challenge to obtain atomic surface for chemical mechanical polishing (CMP). Furthermore, toxic and polluted slurries are usually applied to CMP, resulting in the potential threat to the environment. To solve these items, novel green CMP was developed for a Ti alloy, containing lanthanum‑cerium oxyfluoride, silica, citric acid, hydrogen peroxide, glycine and deionized water. After CMP, atomic surface with surface roughness Sa of 0.155 nm is achieved, at a measurement area of 50 × 50 μm2, and the material removal rate (MRR) is 20.16 μm/h. To the best of our knowledge, for an atomic surface, the surface roughness and MRR are both the best for a Ti alloy. CMP mechanisms are elucidated by electrochemical measurements, X-ray photoelectron spectroscopy and Fourier transform infrared spectroscopy. Firstly, Ti alloy was oxidized by hydrogen peroxide, generating oxides of Ti and aluminum (Al). The oxides were dissolved by hydrogen ions derived from citric acid. Ti and Al ions were chelated with hydrogen peroxide and citric acid, respectively. Chelation formulas were suggested between Al ions and citric acid. Finally, the soft oxidized layer on the surface of Ti alloy was removed by abrasives and a polishing pad. The developed green CMP proposes new insights to achieve atomic surface on a Ti alloy with a high MRR, providing a novel method to polishing difficult-to-process material.
{"title":"Atomic surface of titanium alloy using novel chemical mechanical polishing with rare earth composite abrasives","authors":"Huiguang Sun ,&nbsp;Zhenyu Zhang ,&nbsp;Zihang Xue ,&nbsp;Hongxiu Zhou ,&nbsp;Zaiming Geng ,&nbsp;Chuanshi Cheng ,&nbsp;Leilei Chen ,&nbsp;Ye Tian","doi":"10.1016/j.jmapro.2024.12.036","DOIUrl":"10.1016/j.jmapro.2024.12.036","url":null,"abstract":"<div><div>Titanium (Ti) alloy is a typical difficult-to-process material, rising a challenge to obtain atomic surface for chemical mechanical polishing (CMP). Furthermore, toxic and polluted slurries are usually applied to CMP, resulting in the potential threat to the environment. To solve these items, novel green CMP was developed for a Ti alloy, containing lanthanum‑cerium oxyfluoride, silica, citric acid, hydrogen peroxide, glycine and deionized water. After CMP, atomic surface with surface roughness Sa of 0.155 nm is achieved, at a measurement area of 50 × 50 μm<sup>2</sup>, and the material removal rate (MRR) is 20.16 μm/h. To the best of our knowledge, for an atomic surface, the surface roughness and MRR are both the best for a Ti alloy. CMP mechanisms are elucidated by electrochemical measurements, X-ray photoelectron spectroscopy and Fourier transform infrared spectroscopy. Firstly, Ti alloy was oxidized by hydrogen peroxide, generating oxides of Ti and aluminum (Al). The oxides were dissolved by hydrogen ions derived from citric acid. Ti and Al ions were chelated with hydrogen peroxide and citric acid, respectively. Chelation formulas were suggested between Al ions and citric acid. Finally, the soft oxidized layer on the surface of Ti alloy was removed by abrasives and a polishing pad. The developed green CMP proposes new insights to achieve atomic surface on a Ti alloy with a high MRR, providing a novel method to polishing difficult-to-process material.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 79-89"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132273","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
A monitoring method for local defects in laser additive manufacturing process based on molten pool spatiotemporal information fusion
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.048
Xinyu Ding, Ming Yin, Luofeng Xie, Kaiyu Niu, Yuhang Zhang, Ke Peng
Online monitoring is a key technology for improving the quality of laser additive manufacturing (AM). However, current online monitoring techniques primarily focus on the transient spatial features of process state information and insufficiently account for the spatiotemporal features contained in the evolution of the molten pool in the layer-by-layer deposition process of laser AM. To address this problem, this paper proposes an online monitoring method based on molten pool spatiotemporal information fusion to predict local defects in the laser AM process. We utilized a coaxially integrated Charge-Coupled Device (CCD) camera to capture the molten pool information throughout the printing process. Based on the spatiotemporal correspondence between these molten pool images and local defects, we constructed an experimental dataset. In addition, considering the physical process of layer-by-layer deposition, we propose a spatiotemporal fusion neural network (STFNN) to establish a mapping relationship between the spatiotemporal information contained in the molten pool image sequences and local defects. A temporal information extraction module is designed to capture the spatiotemporal characteristics contained in molten pool images within the same layer and across different layers during the process. Concurrently, a spatial information extraction module is introduced to extract transient spatial features from process images, and a feature fusion module is implemented to integrate high-level features. Compared to methods that extract transient spatial features from the molten pool image, the STFNN model exhibits a significant improvement in defect prediction accuracy. Furthermore, experimental results show that the monitoring method considering both intra-layer and inter-layer spatiotemporal information contained in the molten pool has better porosity detection than those considering only intra-layer or inter-layer spatiotemporal features.
{"title":"A monitoring method for local defects in laser additive manufacturing process based on molten pool spatiotemporal information fusion","authors":"Xinyu Ding,&nbsp;Ming Yin,&nbsp;Luofeng Xie,&nbsp;Kaiyu Niu,&nbsp;Yuhang Zhang,&nbsp;Ke Peng","doi":"10.1016/j.jmapro.2024.12.048","DOIUrl":"10.1016/j.jmapro.2024.12.048","url":null,"abstract":"<div><div>Online monitoring is a key technology for improving the quality of laser additive manufacturing (AM). However, current online monitoring techniques primarily focus on the transient spatial features of process state information and insufficiently account for the spatiotemporal features contained in the evolution of the molten pool in the layer-by-layer deposition process of laser AM. To address this problem, this paper proposes an online monitoring method based on molten pool spatiotemporal information fusion to predict local defects in the laser AM process. We utilized a coaxially integrated Charge-Coupled Device (CCD) camera to capture the molten pool information throughout the printing process. Based on the spatiotemporal correspondence between these molten pool images and local defects, we constructed an experimental dataset. In addition, considering the physical process of layer-by-layer deposition, we propose a spatiotemporal fusion neural network (STFNN) to establish a mapping relationship between the spatiotemporal information contained in the molten pool image sequences and local defects. A temporal information extraction module is designed to capture the spatiotemporal characteristics contained in molten pool images within the same layer and across different layers during the process. Concurrently, a spatial information extraction module is introduced to extract transient spatial features from process images, and a feature fusion module is implemented to integrate high-level features. Compared to methods that extract transient spatial features from the molten pool image, the STFNN model exhibits a significant improvement in defect prediction accuracy. Furthermore, experimental results show that the monitoring method considering both intra-layer and inter-layer spatiotemporal information contained in the molten pool has better porosity detection than those considering only intra-layer or inter-layer spatiotemporal features.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 372-383"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131701","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
Contact force stabilization based on off-line trajectory correction in automated fiber placement
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.056
Lei Miao , Weidong Zhu , Wei Liang , Jiahe Ma , Xiaokang Xu , Zhijia Cai , Shubin Zhao , Yingjie Guo , Yinglin Ke
Automated fiber placement (AFP) is a key technology in aerospace manufacturing, in which the maintenance of rated load is a necessary condition for high-quality forming of composite parts. In order to realize the continuous and stable contact between the flexible roller and the complex mold in the process of robotic AFP, a constant force stabilization method based on off-line trajectory correction is proposed in this paper. In this method, the robot stiffness model and the contact mechanics model proposed in the previous work are used to accurately predict the robot deformation and roller deformation. The two kinds of deformation are compensated to the initial trajectory to keep the distance between the robot end and the roller constant, so as to reduce the burden of the pneumatic system and achieve the stability of the contact force. Static loading experiments demonstrate the accuracy of the proposed method for trajectory correction, and dynamic loading experiments verify the effectiveness of the proposed method for suppressing contact force fluctuations. Experimental results show that this method reduces the maximum error of contact force control from 18.3 % to 7.5 %. The experiment of fiber placement further elucidated the engineering value of this method for laying quality improvement.
{"title":"Contact force stabilization based on off-line trajectory correction in automated fiber placement","authors":"Lei Miao ,&nbsp;Weidong Zhu ,&nbsp;Wei Liang ,&nbsp;Jiahe Ma ,&nbsp;Xiaokang Xu ,&nbsp;Zhijia Cai ,&nbsp;Shubin Zhao ,&nbsp;Yingjie Guo ,&nbsp;Yinglin Ke","doi":"10.1016/j.jmapro.2024.12.056","DOIUrl":"10.1016/j.jmapro.2024.12.056","url":null,"abstract":"<div><div>Automated fiber placement (AFP) is a key technology in aerospace manufacturing, in which the maintenance of rated load is a necessary condition for high-quality forming of composite parts. In order to realize the continuous and stable contact between the flexible roller and the complex mold in the process of robotic AFP, a constant force stabilization method based on off-line trajectory correction is proposed in this paper. In this method, the robot stiffness model and the contact mechanics model proposed in the previous work are used to accurately predict the robot deformation and roller deformation. The two kinds of deformation are compensated to the initial trajectory to keep the distance between the robot end and the roller constant, so as to reduce the burden of the pneumatic system and achieve the stability of the contact force. Static loading experiments demonstrate the accuracy of the proposed method for trajectory correction, and dynamic loading experiments verify the effectiveness of the proposed method for suppressing contact force fluctuations. Experimental results show that this method reduces the maximum error of contact force control from 18.3 % to 7.5 %. The experiment of fiber placement further elucidated the engineering value of this method for laying quality improvement.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 832-850"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131740","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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