Pub Date : 2024-11-12DOI: 10.1016/j.jmapro.2024.11.003
Hui Huang , Yanli Wang , Yong Chae Lim , Eric Boettcher , Zhili Feng
Multi-material joining of lightweight structures is essential to reduce vehicle weight for more energy savings and less greenhouse gas emission. However, mismatch of thermal expansion coefficient for dissimilar materials during the paint baking process can induce part distortion and joint failure for adhesive bonding. In the present work, a thermomechanical model based on contact mechanics and large deformation theory was developed for dissimilar high-strength Al alloy and steel components to study the distortion mechanism and influential factors of the residual gap. The established model was used to optimize joint conditions, such as pitch distance and part geometry. When a weld pitch is shorter than 100 mm, the maximum gap between Al and steel part can be greatly reduced to 0.1 mm, and the local stress and plastic strain around the joint during the oven heating and cooling cycle are also substantially reduced compared with the long pitch case (900 mm). The numerical modeling results revealed that a comparable bending stiffness ratio between the steel and Al cross sections is critical to the minimization of gap and distortion under paint baking condition. Digital image correlation technique was used to measure the overall part distortion and local strain distribution that were used to validate the model prediction. Weld bonding (adhesive bonding with friction bit joining) process was successfully employed to join Al to steel component without gap opening in adhesive after the paint baking and cooling.
{"title":"Mitigation of distortion of Al/steel part under simulated paint baking condition: Experiment and numerical model studies","authors":"Hui Huang , Yanli Wang , Yong Chae Lim , Eric Boettcher , Zhili Feng","doi":"10.1016/j.jmapro.2024.11.003","DOIUrl":"10.1016/j.jmapro.2024.11.003","url":null,"abstract":"<div><div>Multi-material joining of lightweight structures is essential to reduce vehicle weight for more energy savings and less greenhouse gas emission. However, mismatch of thermal expansion coefficient for dissimilar materials during the paint baking process can induce part distortion and joint failure for adhesive bonding. In the present work, a thermomechanical model based on contact mechanics and large deformation theory was developed for dissimilar high-strength Al alloy and steel components to study the distortion mechanism and influential factors of the residual gap. The established model was used to optimize joint conditions, such as pitch distance and part geometry. When a weld pitch is shorter than 100 mm, the maximum gap between Al and steel part can be greatly reduced to 0.1 mm, and the local stress and plastic strain around the joint during the oven heating and cooling cycle are also substantially reduced compared with the long pitch case (900 mm). The numerical modeling results revealed that a comparable bending stiffness ratio between the steel and Al cross sections is critical to the minimization of gap and distortion under paint baking condition. Digital image correlation technique was used to measure the overall part distortion and local strain distribution that were used to validate the model prediction. Weld bonding (adhesive bonding with friction bit joining) process was successfully employed to join Al to steel component without gap opening in adhesive after the paint baking and cooling.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 494-505"},"PeriodicalIF":6.1,"publicationDate":"2024-11-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657385","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}
Pub Date : 2024-11-12DOI: 10.1016/j.jmapro.2024.11.002
Kai Chang, Yi Tan, Rusheng Bai, Lidan Ning, Gengyi Dong, Pengting Li, Yinong Wang
The first proposal of using Electron beam drip melting (EBDM) technology to prepare 〈001〉 oriented columnar grain superalloy was prepared. The study investigated the effects of the EBDM on the microstructure of FGH4096 alloy and the evolution of microstructure during the homogenization process, providing a solid foundation for subsequent thermal deformation processes. Compared to traditional melting methods, the secondary dendrite arm spacing of the EBDM alloy has been significantly reduced by over 40 %, with a 47.5 % decrease in the size of the γ’ phase in the dendrite arm regions. The size of the γ’ phase in the interdendritic regions has decreased by 28.9 %. The size and number of pores in superalloys produced by EBDM are significantly reduced, with a decrease in porosity of approximately one order of magnitude. The high temperature gradients and melt convection effects in the EBDM process promote an increase in the solute boundary layer thickness, significantly reducing both macroscopic and microscopic segregation. The EBDM process can generate relatively high internal residual stresses. By conducting homogenization treatment to control crystal orientation, it is possible to retain the advantages of columnar grain thermal deformation while using the residual stresses that are retained to provide activation energy for subsequent thermal deformation processes. This significantly enhances the thermal deformation capabilities of FGH4096 alloy.
{"title":"A novel cast & wrought FGH4096 superalloy with refined microstructures prepared by electron beam drip melting technology and its homogenization behavior","authors":"Kai Chang, Yi Tan, Rusheng Bai, Lidan Ning, Gengyi Dong, Pengting Li, Yinong Wang","doi":"10.1016/j.jmapro.2024.11.002","DOIUrl":"10.1016/j.jmapro.2024.11.002","url":null,"abstract":"<div><div>The first proposal of using Electron beam drip melting (EBDM) technology to prepare 〈001〉 oriented columnar grain superalloy was prepared. The study investigated the effects of the EBDM on the microstructure of FGH4096 alloy and the evolution of microstructure during the homogenization process, providing a solid foundation for subsequent thermal deformation processes. Compared to traditional melting methods, the secondary dendrite arm spacing of the EBDM alloy has been significantly reduced by over 40 %, with a 47.5 % decrease in the size of the γ’ phase in the dendrite arm regions. The size of the γ’ phase in the interdendritic regions has decreased by 28.9 %. The size and number of pores in superalloys produced by EBDM are significantly reduced, with a decrease in porosity of approximately one order of magnitude. The high temperature gradients and melt convection effects in the EBDM process promote an increase in the solute boundary layer thickness, significantly reducing both macroscopic and microscopic segregation. The EBDM process can generate relatively high internal residual stresses. By conducting homogenization treatment to control crystal orientation, it is possible to retain the advantages of columnar grain thermal deformation while using the residual stresses that are retained to provide activation energy for subsequent thermal deformation processes. This significantly enhances the thermal deformation capabilities of FGH4096 alloy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 451-466"},"PeriodicalIF":6.1,"publicationDate":"2024-11-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657388","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}
Pub Date : 2024-11-11DOI: 10.1016/j.jmapro.2024.10.070
Peng Zhang , Zheming Chen , Liuwei Guo , Chaoran Li , Shuyang Lu , Jianfei Sun
This investigation delves into the plastic deformation mechanisms responsible for the distinctive chip formation of Invar 36 alloy, marked by features of cleavage and folding instabilities during machining. This study unveils the flow characteristics of Invar 36 alloy by conducting cutting experiments and material property tests, leading to the formulation of flow stress models. Employing polycrystalline finite element simulation, the research illuminates how intergranular compression can induce surface bulging, subsequently triggering the initiation of cracks under tensile stress. As cutting speeds escalate, an intensification in plastic flow begets increasingly pronounced and frequent chip serrations. When speeds surpass 200 m/min, elevated temperatures and strain rates foster material buckling and adhesion to the tool's rake face, fostering the emergence of large-scale and subsidiary folds. This “fan-like” chip architecture precipitates a self-blocking effect, which in turn generates significant cutting forces and severe oscillations. An analysis via a mathematical-physical model reveals that the oscillation in cutting force incite the material's inertial responses, catalyzing abrupt shifts in shear strain and shear strain rate, and eventually leading to cracks and segmentation within the cutting zone. Finally, the research briefly discussed on the ramifications of these alterations in the cutting flow mechanism on tool wear and surface quality in the practical machining of Invar 36 alloy, alongside an outline of prospective research.
{"title":"Machining of Invar 36 alloy: Chip-flow behaviors and formation mechanisms","authors":"Peng Zhang , Zheming Chen , Liuwei Guo , Chaoran Li , Shuyang Lu , Jianfei Sun","doi":"10.1016/j.jmapro.2024.10.070","DOIUrl":"10.1016/j.jmapro.2024.10.070","url":null,"abstract":"<div><div>This investigation delves into the plastic deformation mechanisms responsible for the distinctive chip formation of Invar 36 alloy, marked by features of cleavage and folding instabilities during machining. This study unveils the flow characteristics of Invar 36 alloy by conducting cutting experiments and material property tests, leading to the formulation of flow stress models. Employing polycrystalline finite element simulation, the research illuminates how intergranular compression can induce surface bulging, subsequently triggering the initiation of cracks under tensile stress. As cutting speeds escalate, an intensification in plastic flow begets increasingly pronounced and frequent chip serrations. When speeds surpass 200 m/min, elevated temperatures and strain rates foster material buckling and adhesion to the tool's rake face, fostering the emergence of large-scale and subsidiary folds. This “fan-like” chip architecture precipitates a self-blocking effect, which in turn generates significant cutting forces and severe oscillations. An analysis via a mathematical-physical model reveals that the oscillation in cutting force incite the material's inertial responses, catalyzing abrupt shifts in shear strain and shear strain rate, and eventually leading to cracks and segmentation within the cutting zone. Finally, the research briefly discussed on the ramifications of these alterations in the cutting flow mechanism on tool wear and surface quality in the practical machining of Invar 36 alloy, alongside an outline of prospective research.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 477-493"},"PeriodicalIF":6.1,"publicationDate":"2024-11-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657386","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}
Pub Date : 2024-11-09DOI: 10.1016/j.jmapro.2024.10.057
Yifei Hu , Xiaoliang Jin , Xin Jiang , Zhiming Zheng
Multiaxis micromachining centers, designed for precision in miniature parts due to their high degrees of freedom, face significant challenges in motion planning to achieve high accuracy and speed. This paper presents a trajectory generation algorithm for a novel dual-stage 9-axis micro milling machine, comprising a Cartesian 3-axis stage and a high-bandwidth 6-degree-of-freedom magnetically levitated table. To address the inherent challenge of kinematic redundancy, the inverse kinematics model is developed to determine the position of each axis corresponding to the desired tool position and orientation. The feedrate is determined by considering the kinematics constraints of all nine axes. With the tool paths in the machine coordinate system fitted using B-spline curves, two linear optimization problems are formulated and solved to obtain the feedrate profile. Finally, interpolation points are calculated using a feedback method to obtain the position commands. The proposed method outperforms traditional methods using the Moore Penrose pseudoinverse of the Jacobian matrix, reducing cycle time by up to 44.55 % and contour error by up to 15.64 %, demonstrating significant efficiency and accuracy improvements.
{"title":"Inverse kinematics model and trajectory generation of a dual-stage micro milling machine","authors":"Yifei Hu , Xiaoliang Jin , Xin Jiang , Zhiming Zheng","doi":"10.1016/j.jmapro.2024.10.057","DOIUrl":"10.1016/j.jmapro.2024.10.057","url":null,"abstract":"<div><div>Multiaxis micromachining centers, designed for precision in miniature parts due to their high degrees of freedom, face significant challenges in motion planning to achieve high accuracy and speed. This paper presents a trajectory generation algorithm for a novel dual-stage 9-axis micro milling machine, comprising a Cartesian 3-axis stage and a high-bandwidth 6-degree-of-freedom magnetically levitated table. To address the inherent challenge of kinematic redundancy, the inverse kinematics model is developed to determine the position of each axis corresponding to the desired tool position and orientation. The feedrate is determined by considering the kinematics constraints of all nine axes. With the tool paths in the machine coordinate system fitted using B-spline curves, two linear optimization problems are formulated and solved to obtain the feedrate profile. Finally, interpolation points are calculated using a feedback method to obtain the position commands. The proposed method outperforms traditional methods using the Moore Penrose pseudoinverse of the Jacobian matrix, reducing cycle time by up to 44.55 % and contour error by up to 15.64 %, demonstrating significant efficiency and accuracy improvements.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 425-450"},"PeriodicalIF":6.1,"publicationDate":"2024-11-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657315","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}
Pub Date : 2024-11-09DOI: 10.1016/j.jmapro.2024.10.086
Hang Zhang , Xiaoyu Sun , Xuebo Xu , Feng Zhao , Jianglong Cai , Xin Guo , Ziye He , Dichen Li
Laser polishing represents an advanced surface treatment method that decreases surface roughness by utilizing the interaction between the laser beam and the material. Nevertheless, the laser polishing process often introduces new surface structures with certain fluctuations, which affect the final polishing outcome. In this paper, a two-dimensional cross-sectional numerical model integrating fluid flow, heat transfer, and material vaporization was developed to simulate the temperature field, momentum and surface morphologies of the polished sample. This model was used to investigate the generation mechanism of “M”-shaped surface structures induced by Gaussian continuous-wave (CW) laser scanning on NiP alloy. The surface structure was significantly influenced by the combined effects of material properties, laser energy distribution, and various surface forces. Comparison between simulated and experimental surface structures showed a deviation of 2.81 % in the distance between two bulges of the “M”-shaped surface structure () and a deviation of 6.24 % in the bulge height (). The model was further employed to simulate the profiles of laser multi-track polishing at different track offsets. The research indicated that the optimal polishing occurs when the laser scanning track offset () equals . Multi-track laser experiments confirmed the simulation predictions and revealed the potential of CW laser in surface configuration. This study successfully advances theoretical research on laser polishing and enhances the efficiency of selecting laser polishing process parameters.
{"title":"Numerical simulation of surface structures in single and multi-track laser polishing of NiP alloy","authors":"Hang Zhang , Xiaoyu Sun , Xuebo Xu , Feng Zhao , Jianglong Cai , Xin Guo , Ziye He , Dichen Li","doi":"10.1016/j.jmapro.2024.10.086","DOIUrl":"10.1016/j.jmapro.2024.10.086","url":null,"abstract":"<div><div>Laser polishing represents an advanced surface treatment method that decreases surface roughness by utilizing the interaction between the laser beam and the material. Nevertheless, the laser polishing process often introduces new surface structures with certain fluctuations, which affect the final polishing outcome. In this paper, a two-dimensional cross-sectional numerical model integrating fluid flow, heat transfer, and material vaporization was developed to simulate the temperature field, momentum and surface morphologies of the polished sample. This model was used to investigate the generation mechanism of “M”-shaped surface structures induced by Gaussian continuous-wave (CW) laser scanning on Ni<img>P alloy. The surface structure was significantly influenced by the combined effects of material properties, laser energy distribution, and various surface forces. Comparison between simulated and experimental surface structures showed a deviation of 2.81 % in the distance between two bulges of the “M”-shaped surface structure (<span><math><mi>d</mi></math></span>) and a deviation of 6.24 % in the bulge height (<span><math><mi>h</mi></math></span>). The model was further employed to simulate the profiles of laser multi-track polishing at different track offsets. The research indicated that the optimal polishing occurs when the laser scanning track offset (<span><math><mo>∆</mo><mi>d</mi></math></span>) equals <span><math><mi>d</mi><mo>/</mo><mn>2</mn></math></span>. Multi-track laser experiments confirmed the simulation predictions and revealed the potential of CW laser in surface configuration. This study successfully advances theoretical research on laser polishing and enhances the efficiency of selecting laser polishing process parameters.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 404-415"},"PeriodicalIF":6.1,"publicationDate":"2024-11-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657390","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}
Pub Date : 2024-11-09DOI: 10.1016/j.jmapro.2024.10.076
Xia Liangliang , Xu Yong , Xie Wenlong , Li Jie , Liu Xuefei , Artur I. Pokrovsky , Zhang Shi-Hong
Springback is a critical factor in controlling the tolerance of thin-walled, curved components during manufacturing. This study proposes a strategy that utilizes impact hydroforming to eliminate springback instead of the traditional method of modifying the die for compensation. Bending tests were conducted on the 2024 aluminum alloy sheet with a bending angle of 120° and bending radius of 30 mm under three different loading modes, i.e. quasi-static rigid punch bending (QSR), high-speed rigid punch bending (HSR), and impact hydroforming (IHF) bending. Corresponding finite element simulations of these loading modes were also performed, and the simulated springback variations closely matched the experimental results. The experiments revealed that springback decreased with an increase in strain rate, and the use of a liquid medium further facilitated or even eliminated springback. The deformation sequence, strain neutral layer, principal stress, and equivalent plastic strain distribution of the sheet were analyzed under each loading mode. Two primary reasons for the reduction in springback were identified: the high strain rate induced stress relaxation and energy release, and the liquid medium altering the deformation sequence of the sheet, leading to shear deformation. These findings offer a new strategy for achieving forming precision, high efficiency, and low-cost manufacturing complex thin-walled components of made from aviation aluminum alloy.
回弹是控制薄壁曲面部件制造过程中公差的关键因素。本研究提出了一种利用冲击液压成形消除回弹的策略，而非传统的修改模具进行补偿的方法。在准静态刚性冲压弯曲（QSR）、高速刚性冲压弯曲（HSR）和冲击液压成形弯曲（IHF）三种不同加载模式下，对弯曲角度为 120°、弯曲半径为 30 mm 的 2024 铝合金板材进行了弯曲试验。还对这些加载模式进行了相应的有限元模拟，模拟的回弹变化与实验结果非常吻合。实验结果表明，回弹随应变速率的增加而减少，而液体介质的使用进一步促进甚至消除了回弹。分析了每种加载模式下板材的变形顺序、应变中性层、主应力和等效塑性应变分布。研究发现了回弹减少的两个主要原因：高应变率引起的应力松弛和能量释放，以及液体介质改变了板材的变形顺序，导致剪切变形。这些发现为实现航空铝合金复杂薄壁部件的成型精度、高效率和低成本制造提供了一种新策略。
{"title":"A novel strategy for reducing sheet springback by coupled with high strain rate and shear deformation via impact hydroforming","authors":"Xia Liangliang , Xu Yong , Xie Wenlong , Li Jie , Liu Xuefei , Artur I. Pokrovsky , Zhang Shi-Hong","doi":"10.1016/j.jmapro.2024.10.076","DOIUrl":"10.1016/j.jmapro.2024.10.076","url":null,"abstract":"<div><div>Springback is a critical factor in controlling the tolerance of thin-walled, curved components during manufacturing. This study proposes a strategy that utilizes impact hydroforming to eliminate springback instead of the traditional method of modifying the die for compensation. Bending tests were conducted on the 2024 aluminum alloy sheet with a bending angle of 120° and bending radius of 30 mm under three different loading modes, i.e. quasi-static rigid punch bending (QSR), high-speed rigid punch bending (HSR), and impact hydroforming (IHF) bending. Corresponding finite element simulations of these loading modes were also performed, and the simulated springback variations closely matched the experimental results. The experiments revealed that springback decreased with an increase in strain rate, and the use of a liquid medium further facilitated or even eliminated springback. The deformation sequence, strain neutral layer, principal stress, and equivalent plastic strain distribution of the sheet were analyzed under each loading mode. Two primary reasons for the reduction in springback were identified: the high strain rate induced stress relaxation and energy release, and the liquid medium altering the deformation sequence of the sheet, leading to shear deformation. These findings offer a new strategy for achieving forming precision, high efficiency, and low-cost manufacturing complex thin-walled components of made from aviation aluminum alloy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 392-403"},"PeriodicalIF":6.1,"publicationDate":"2024-11-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657313","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}
Pub Date : 2024-11-09DOI: 10.1016/j.jmapro.2024.11.005
Nadeem Fayaz Lone , Namrata Gangil , Dhruv Bajaj , Amit Arora , Daolun Chen , Arshad Noor Siddiquee
4D printing refers to the additive manufacturing of a component by incorporating smart materials. The smart materials add the “4th dimension” to 3D-printing by altering the shape/functionality/configuration of the part in response to external stimulus such as heat, stress, pH, electric field, etc. In the current study, shape memory alloy (SMA) plugs were implanted into mild-steel via gas metal arc welding (GMAW) assisted wire-arc additive manufacturing (WAAM). The NiTi SMA powder was employed as secondary addition within the printed layers, while the FeMnSi based alloy evolved in-situ during the 4D-printing process. Significant elemental heterogeneity was found in the Fe-Mn-Si based SMA plugs containing NiFe rich solidified droplets, owing to the composition of the wire used for deposition. The NiFe rich phases depicted the substitution of Ti by Fe in the NiTi pre-cursors. The large SMA plugs incorporated into the printed mild steel depicted the formation of a macro composite structure. The presented results are expected to considerably reduce the cost of SMA application through the printing of novel monolithic SMA-steel composites using wires and SMA powders as raw materials.
4D 打印是指采用智能材料对部件进行增材制造。智能材料可在热量、应力、pH 值、电场等外部刺激下改变零件的形状/功能/配置，从而为三维打印增添 "第四维"。在当前的研究中，通过气体金属弧焊（GMAW）辅助线弧增材制造（WAAM）将形状记忆合金（SMA）塞植入低碳钢中。在 4D 打印过程中，镍钛 SMA 粉末被用作打印层内的二次添加物，而基于铁锰硅的合金则在原位演化。由于沉积所用金属丝的成分不同，在含有富含镍铁合金凝固液滴的铁锰硅基 SMA 塞中发现了明显的元素异质性。富含 NiFe 的物相表明，在 NiTi 前驱体中 Ti 被 Fe 取代。印刷低碳钢中的大块 SMA 塞描述了宏观复合结构的形成。通过使用金属丝和 SMA 粉末作为原材料打印新型整体 SMA 钢复合材料，上述结果有望大大降低 SMA 的应用成本。
{"title":"Innovating 4D-printed microstructures via gas metal arc welding assisted wire-arc additive manufacturing","authors":"Nadeem Fayaz Lone , Namrata Gangil , Dhruv Bajaj , Amit Arora , Daolun Chen , Arshad Noor Siddiquee","doi":"10.1016/j.jmapro.2024.11.005","DOIUrl":"10.1016/j.jmapro.2024.11.005","url":null,"abstract":"<div><div>4D printing refers to the additive manufacturing of a component by incorporating smart materials. The smart materials add the “4th dimension” to 3D-printing by altering the shape/functionality/configuration of the part in response to external stimulus such as heat, stress, pH, electric field, etc. In the current study, shape memory alloy (SMA) plugs were implanted into mild-steel via gas metal arc welding (GMAW) assisted wire-arc additive manufacturing (WAAM). The NiTi SMA powder was employed as secondary addition within the printed layers, while the FeMnSi based alloy evolved in-situ during the 4D-printing process. Significant elemental heterogeneity was found in the Fe-Mn-Si based SMA plugs containing Ni<img>Fe rich solidified droplets, owing to the composition of the wire used for deposition. The Ni<img>Fe rich phases depicted the substitution of Ti by Fe in the NiTi pre-cursors. The large SMA plugs incorporated into the printed mild steel depicted the formation of a macro composite structure. The presented results are expected to considerably reduce the cost of SMA application through the printing of novel monolithic SMA-steel composites using wires and SMA powders as raw materials.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 416-424"},"PeriodicalIF":6.1,"publicationDate":"2024-11-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657389","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}
Pub Date : 2024-11-08DOI: 10.1016/j.jmapro.2024.10.074
Carlos Rubio-González , José de Jesús Ku-Herrera , Jyhwen Wang , Albert Patterson , Jorge A. Soto-Cajiga , Oscar Olvera-Silva
The piezoresistive response of specimens made by electrically conductive polylactic acid (PLA) under monotonic and cyclic flexural loading was experimentally investigated. A material extrusion process was utilized to 3D print the conductive PLA/carbon black nanocomposite samples using three infill patterns and three infill ratios. Then three-point bending tests, and electrical resistance measurements, were simultaneously conducted on beam-type specimens. The results of the electromechanical tests demonstrated that the 3D printed samples show outstanding piezoresistive sensing characteristics with excellent cyclic stability and reproducibility suitable for in-situ damage detection and strain monitoring through their electrical resistance change. Determination of gauge factors of specimens with different infill ratios and patterns exhibited a significant sensitivity even at low infill ratio. The potential of the piezoresistive property of conductive PLA/carbon black nanocomposite was examined by proposing 3D printed sensors for strain monitoring. The results demonstrated that conductive feedstock can be successfully processed by this material extrusion technique to develop advanced 3D printing sensing solutions. The applicability of the piezoresistive property of conductive cellular structures 3D printed with PLA/carbon black feedstock as a suitable technique for structural health monitoring was demonstrated.
实验研究了由导电聚乳酸（PLA）制成的试样在单调和循环挠曲加载下的压阻响应。利用材料挤压工艺，采用三种填充模式和三种填充比例，三维打印出导电聚乳酸/炭黑纳米复合材料样品。然后在梁型试样上同时进行了三点弯曲试验和电阻测量。机电测试结果表明，3D 打印样品具有出色的压阻传感特性，具有极佳的周期稳定性和可重复性，适合通过其电阻变化进行原位损伤检测和应变监测。对不同填充比和图案的试样进行测量，即使在低填充比的情况下也能显示出显著的灵敏度。通过提出用于应变监测的 3D 打印传感器，研究了导电聚乳酸/炭黑纳米复合材料压阻特性的潜力。结果表明，导电原料可以通过这种材料挤压技术成功加工，从而开发出先进的 3D 打印传感解决方案。用聚乳酸/炭黑原料三维打印的导电蜂窝结构的压阻特性作为结构健康监测的一种合适技术的适用性得到了证明。
{"title":"Effect of printing parameters on the mechanical and piezoresistive response of cellular structures manufactured with a conductive polylactic acid nanocomposite through a material extrusion process","authors":"Carlos Rubio-González , José de Jesús Ku-Herrera , Jyhwen Wang , Albert Patterson , Jorge A. Soto-Cajiga , Oscar Olvera-Silva","doi":"10.1016/j.jmapro.2024.10.074","DOIUrl":"10.1016/j.jmapro.2024.10.074","url":null,"abstract":"<div><div>The piezoresistive response of specimens made by electrically conductive polylactic acid (PLA) under monotonic and cyclic flexural loading was experimentally investigated. A material extrusion process was utilized to 3D print the conductive PLA/carbon black nanocomposite samples using three infill patterns and three infill ratios. Then three-point bending tests, and electrical resistance measurements, were simultaneously conducted on beam-type specimens. The results of the electromechanical tests demonstrated that the 3D printed samples show outstanding piezoresistive sensing characteristics with excellent cyclic stability and reproducibility suitable for in-situ damage detection and strain monitoring through their electrical resistance change. Determination of gauge factors of specimens with different infill ratios and patterns exhibited a significant sensitivity even at low infill ratio. The potential of the piezoresistive property of conductive PLA/carbon black nanocomposite was examined by proposing 3D printed sensors for strain monitoring. The results demonstrated that conductive feedstock can be successfully processed by this material extrusion technique to develop advanced 3D printing sensing solutions. The applicability of the piezoresistive property of conductive cellular structures 3D printed with PLA/carbon black feedstock as a suitable technique for structural health monitoring was demonstrated.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 375-391"},"PeriodicalIF":6.1,"publicationDate":"2024-11-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657314","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}
Pub Date : 2024-11-06DOI: 10.1016/j.jmapro.2024.10.080
Bing Wu , Rong Yi , Xuemiao Ding , Tom Chiu , Quanpeng He , Hui Deng
Atmospheric plasma etching-based machining methods generally suffer from surface roughness deterioration. To achieve an atomic-scale smooth surface of Si via purely plasma etching, clarifying the etching evolution and mechanism is essential. In this study, we study surface evolution and smoothening mechanisms from the perspective of plasma etching modes comprehensively. The morphology and roughness evolutions of isotropic, orientation-selective, and atom-selective etching are investigated, respectively. The semi-finishing effect is realized through the growing and merging of hemispherical pits during isotropic etching, with the surface roughness being reduced from 103 nm to 0.79 nm. Orientation-selective etching is a roughening process, transforming square-opening pits into pyramid structures. Under the atom-selective mode, an atomically smooth surface with Sa 0.17 nm can be obtained. The top-down smoothing process of atom-selective is much more efficient than isotropic etching. Atom-selective etching with a maximum removal rate of 22 μm/min enables the rapid thinning of Si substrate thickness from 715 μm to 90.4 μm within 45 min. Additionally, atom-selective etching is a universal polishing approach regardless of pre-processed methods and is a damage-less process. This paper provides a promising strategy for atomic and close-to-atomic scale manufacturing.
{"title":"Surface evolution mechanism for atomic-scale smoothing of Si via atmospheric pressure plasma etching","authors":"Bing Wu , Rong Yi , Xuemiao Ding , Tom Chiu , Quanpeng He , Hui Deng","doi":"10.1016/j.jmapro.2024.10.080","DOIUrl":"10.1016/j.jmapro.2024.10.080","url":null,"abstract":"<div><div>Atmospheric plasma etching-based machining methods generally suffer from surface roughness deterioration. To achieve an atomic-scale smooth surface of Si via purely plasma etching, clarifying the etching evolution and mechanism is essential. In this study, we study surface evolution and smoothening mechanisms from the perspective of plasma etching modes comprehensively. The morphology and roughness evolutions of isotropic, orientation-selective, and atom-selective etching are investigated, respectively. The semi-finishing effect is realized through the growing and merging of hemispherical pits during isotropic etching, with the surface roughness being reduced from 103 nm to 0.79 nm. Orientation-selective etching is a roughening process, transforming square-opening pits into pyramid structures. Under the atom-selective mode, an atomically smooth surface with <em>S</em>a 0.17 nm can be obtained. The top-down smoothing process of atom-selective is much more efficient than isotropic etching. Atom-selective etching with a maximum removal rate of 22 μm/min enables the rapid thinning of Si substrate thickness from 715 μm to 90.4 μm within 45 min. Additionally, atom-selective etching is a universal polishing approach regardless of pre-processed methods and is a damage-less process. This paper provides a promising strategy for atomic and close-to-atomic scale manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 353-362"},"PeriodicalIF":6.1,"publicationDate":"2024-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142593908","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}
Pub Date : 2024-11-06DOI: 10.1016/j.jmapro.2024.10.049
Lidong Zhao , Zhi Zhao , Limin Ma , Shuyi Li , Zening Men , Lifang Wu
Digital light processing (DLP) 3D printing has attracted significant attention for its rapid printing speed, high accuracy, and diverse applications. However, the continuous DLP printing process releases substantial heat, resulting in a swift temperature rise in the curing area, which may lead to printing failures. Due to the lack of effective means to measure real-time temperature changes of the curing surface during continuous DLP 3D printing, the prevailing approach is to predict temperature variations during printing via numerical simulation. Nevertheless, temperature prediction methods relying solely on numerical simulation tend to be slow and overlook heat exchange dynamics during printing, potentially resulting in prediction inaccuracies, particularly for complex models. To address these issues, this paper proposes a method to combine numerical simulation and a machine learning approach for temperature prediction in the DLP 3D printing process, along with a printing control scheme generation method. Firstly, the order autocatalytic kinetic model considering the light intensity and the Beer–Lambert law are employed to formulate the heat calculation equation for the photopolymer resin curing reaction. Subsequently, a heat exchange calculation equation is established based on Fourier heat conduction law and Newton’s cooling equation. A numerical simulation model for temperature changes during the printing process is then developed by integrating the heat calculation equation, heat exchange calculation equation, and measurement data from Photo-DSC. Furthermore, a temperature measurement device for the printing process is designed to validate the accuracy of the numerical simulation. Following this, an improved Long Short-term Memory (LSTM) network is proposed, using temperature change data generated by the numerical simulation model to train the network for rapid ( ) prediction of temperature changes during printing. Finally, aiming for the shortest printing time, an optimized control scheme planning algorithm and a target function are designed based on the model’s temperature change data and the monomer’s flash point to ensure the temperature remains below this threshold. This algorithm can automatically generate the optimal printing control scheme for any model. Experimental results demonstrate that the proposed temperature prediction method can predict temperature variation accurately. Based on this, the generated printing control scheme can guarantee efficient and high-quality manufacturing for anymodel.
数字光处理（DLP）三维打印因其打印速度快、精度高和应用多样化而备受关注。然而，连续 DLP 打印过程会释放大量热量，导致固化区域温度迅速升高，从而可能导致打印失败。由于缺乏有效的方法来测量连续 DLP 3D 打印过程中固化表面的实时温度变化，目前普遍采用的方法是通过数值模拟来预测打印过程中的温度变化。然而，仅仅依靠数值模拟的温度预测方法往往速度较慢，而且会忽略打印过程中的热交换动态，从而可能导致预测不准确，尤其是对于复杂的模型。为了解决这些问题，本文提出了一种结合数值模拟和机器学习的方法，用于 DLP 3D 打印过程中的温度预测，并提出了一种打印控制方案生成方法。首先，采用考虑光照强度和比尔-朗伯定律的 m+nth 阶自催化动力学模型，建立光聚合物树脂固化反应的热量计算方程。随后，根据傅立叶热传导定律和牛顿冷却方程建立了热交换计算方程。然后，通过整合热量计算公式、热交换计算公式和光致发光扫描仪的测量数据，建立了印刷过程中温度变化的数值模拟模型。此外，还设计了用于印刷过程的温度测量装置，以验证数值模拟的准确性。随后，利用数值模拟模型生成的温度变化数据，提出了一种改进的长短期记忆（LSTM）网络，用于训练网络快速（2×10-4 s/层）预测印刷过程中的温度变化。最后，以最短印刷时间为目标，根据模型的温度变化数据和单体闪点设计了优化控制方案规划算法和目标函数，以确保温度保持在该阈值以下。该算法可为任何模型自动生成最佳印刷控制方案。实验结果表明，所提出的温度预测方法可以准确预测温度变化。在此基础上，生成的印刷控制方案可以保证任何模型的高效和高质量制造。
{"title":"Developing the optimized control scheme for digital light processing 3D printing by combining numerical simulation and machine learning-guided temperature prediction","authors":"Lidong Zhao , Zhi Zhao , Limin Ma , Shuyi Li , Zening Men , Lifang Wu","doi":"10.1016/j.jmapro.2024.10.049","DOIUrl":"10.1016/j.jmapro.2024.10.049","url":null,"abstract":"<div><div>Digital light processing (DLP) 3D printing has attracted significant attention for its rapid printing speed, high accuracy, and diverse applications. However, the continuous DLP printing process releases substantial heat, resulting in a swift temperature rise in the curing area, which may lead to printing failures. Due to the lack of effective means to measure real-time temperature changes of the curing surface during continuous DLP 3D printing, the prevailing approach is to predict temperature variations during printing via numerical simulation. Nevertheless, temperature prediction methods relying solely on numerical simulation tend to be slow and overlook heat exchange dynamics during printing, potentially resulting in prediction inaccuracies, particularly for complex models. To address these issues, this paper proposes a method to combine numerical simulation and a machine learning approach for temperature prediction in the DLP 3D printing process, along with a printing control scheme generation method. Firstly, the <span><math><msup><mrow><mfenced><mrow><mtext>m</mtext><mo>+</mo><mtext>n</mtext></mrow></mfenced></mrow><mrow><mi>t</mi><mi>h</mi></mrow></msup></math></span> order autocatalytic kinetic model considering the light intensity and the Beer–Lambert law are employed to formulate the heat calculation equation for the photopolymer resin curing reaction. Subsequently, a heat exchange calculation equation is established based on Fourier heat conduction law and Newton’s cooling equation. A numerical simulation model for temperature changes during the printing process is then developed by integrating the heat calculation equation, heat exchange calculation equation, and measurement data from Photo-DSC. Furthermore, a temperature measurement device for the printing process is designed to validate the accuracy of the numerical simulation. Following this, an improved Long Short-term Memory (LSTM) network is proposed, using temperature change data generated by the numerical simulation model to train the network for rapid (<span><math><mrow><mn>2</mn><mo>×</mo><msup><mrow><mn>10</mn></mrow><mrow><mo>−</mo><mn>4</mn></mrow></msup></mrow></math></span> <span><math><mrow><mtext>s</mtext><mo>/</mo><mtext>layer</mtext></mrow></math></span>) prediction of temperature changes during printing. Finally, aiming for the shortest printing time, an optimized control scheme planning algorithm and a target function are designed based on the model’s temperature change data and the monomer’s flash point to ensure the temperature remains below this threshold. This algorithm can automatically generate the optimal printing control scheme for any model. Experimental results demonstrate that the proposed temperature prediction method can predict temperature variation accurately. Based on this, the generated printing control scheme can guarantee efficient and high-quality manufacturing for anymodel.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 363-374"},"PeriodicalIF":6.1,"publicationDate":"2024-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142593965","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}
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