Journal of Manufacturing Processes最新文献

英文中文

A layer misalignment printing method for enhancement of mechanical performance in fused filament fabrication: Experiment and modelling

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2025.01.013

Heng Cai , Jiale Xi , Yingpeng He , Yusi Wang , Yuan Chen

There are big limitations in 3D-printed parts for engineering applications due to their weak transverse mechanical properties when using fused filament fabrication (FFF). Accordingly, this study introduces a novel layer misalignment printing (LMP) method inspired by the meso-structural pattern in FFF. First, the effect of printing temperature on mesoscopic structural characteristics in LMP and the conventional approach of layer aligned printing (LAP) were compared and analysed. Second, in view of the periodic distribution characteristics, specific multi-scale numerical models based on the in-plane cohesive method and linear softening constitutive relation were developed to explore the effect of meso-pores on the mechanical properties. The proposed numerical models were applied to predict macroscopic mechanical responses and analyse mesoscopic damage mechanisms. Then, standard test specimens, oriented perpendicular and parallel to the printing direction, were fabricated using both printing methods for quasi-static tensile testing and characterisation. Through microscopic characterisation and statistical analysis, it is found that when using LMP, porosities are decreased by 0.4 %, 5.4 %, and 8.1 % in comparison to those when using LAP, at printing temperatures of 275 °C, 250 °C and 225 °C, respectively. Experimental results show that the average longitudinal and transversal elastic moduli of LMP-based specimens are increased by 7.8 % and 23.5 %, respectively, when compared to LAP-based ones. Meanwhile, the longitudinal and transversal tensile strengths achieve increments by 6.3 % and 26.1 %, respectively. Last, numerical results agree well with experimental results, proving the effectiveness of the proposed multi-scale methods. More importantly, the LMP method is well proven as an effective and promising method to improve the mechanical properties of printed parts via FFF.

{"title":"A layer misalignment printing method for enhancement of mechanical performance in fused filament fabrication: Experiment and modelling","authors":"Heng Cai , Jiale Xi , Yingpeng He , Yusi Wang , Yuan Chen","doi":"10.1016/j.jmapro.2025.01.013","DOIUrl":"10.1016/j.jmapro.2025.01.013","url":null,"abstract":"<div><div>There are big limitations in 3D-printed parts for engineering applications due to their weak transverse mechanical properties when using fused filament fabrication (FFF). Accordingly, this study introduces a novel layer misalignment printing (LMP) method inspired by the meso-structural pattern in FFF. First, the effect of printing temperature on mesoscopic structural characteristics in LMP and the conventional approach of layer aligned printing (LAP) were compared and analysed. Second, in view of the periodic distribution characteristics, specific multi-scale numerical models based on the in-plane cohesive method and linear softening constitutive relation were developed to explore the effect of meso-pores on the mechanical properties. The proposed numerical models were applied to predict macroscopic mechanical responses and analyse mesoscopic damage mechanisms. Then, standard test specimens, oriented perpendicular and parallel to the printing direction, were fabricated using both printing methods for quasi-static tensile testing and characterisation. Through microscopic characterisation and statistical analysis, it is found that when using LMP, porosities are decreased by 0.4 %, 5.4 %, and 8.1 % in comparison to those when using LAP, at printing temperatures of 275 °C, 250 °C and 225 °C, respectively. Experimental results show that the average longitudinal and transversal elastic moduli of LMP-based specimens are increased by 7.8 % and 23.5 %, respectively, when compared to LAP-based ones. Meanwhile, the longitudinal and transversal tensile strengths achieve increments by 6.3 % and 26.1 %, respectively. Last, numerical results agree well with experimental results, proving the effectiveness of the proposed multi-scale methods. More importantly, the LMP method is well proven as an effective and promising method to improve the mechanical properties of printed parts via FFF.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 775-789"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131743","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 quantitative model to determine the Ti content for crack-free AlCuMg alloy in laser powder-bed fusion

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.059

Ziqian Wang , Yuhan Qian , Yakai Xiao , Zijue Tang , Yi Wu , Hua Sun , Tengteng Sun , Xingtian Liu , Haowei Wang , Hongze Wang

A quantitative model for hot cracking prediction is essential for the composition design of non-castable AlCuMg alloys. In present work, the hot cracking prediction model of laser powder-bed fusion (LPBF) processed Ti-modified AlCuMg alloys was built on the basis of time-dependent nucleation theory and non-steady nucleation kinetics. The critical Ti content for crack-free AlCuMg alloy was calculated by this model and then manufactured successfully under the guidance of crack elimination strategy given by model simulation. The microstructure evolution of AlCuMg alloys with both inferior and superior Ti content to the critical value were investigated respectively in detail so that the effectiveness of model could be verified. The correlation among cooling rate, Ti content and Al₃Ti nuclei density was quantified and analyzed so that the formation of hot-tearing cracks could be discussed combined with microstructure evolution and crack susceptibility criterion. This model is promising for simplifying composition design work of high-strength aluminum alloys and further giving guidance on parameter optimization for LPBF manufacturing of non-castable Al alloys.

{"title":"A quantitative model to determine the Ti content for crack-free AlCuMg alloy in laser powder-bed fusion","authors":"Ziqian Wang , Yuhan Qian , Yakai Xiao , Zijue Tang , Yi Wu , Hua Sun , Tengteng Sun , Xingtian Liu , Haowei Wang , Hongze Wang","doi":"10.1016/j.jmapro.2024.12.059","DOIUrl":"10.1016/j.jmapro.2024.12.059","url":null,"abstract":"<div><div>A quantitative model for hot cracking prediction is essential for the composition design of non-castable AlCuMg alloys. In present work, the hot cracking prediction model of laser powder-bed fusion (LPBF) processed Ti-modified AlCuMg alloys was built on the basis of time-dependent nucleation theory and non-steady nucleation kinetics. The critical Ti content for crack-free AlCuMg alloy was calculated by this model and then manufactured successfully under the guidance of crack elimination strategy given by model simulation. The microstructure evolution of AlCuMg alloys with both inferior and superior Ti content to the critical value were investigated respectively in detail so that the effectiveness of model could be verified. The correlation among cooling rate, Ti content and Al<sub>3</sub>Ti nuclei density was quantified and analyzed so that the formation of hot-tearing cracks could be discussed combined with microstructure evolution and crack susceptibility criterion. This model is promising for simplifying composition design work of high-strength aluminum alloys and further giving guidance on parameter optimization for LPBF manufacturing of non-castable Al alloys.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 721-738"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131945","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 an acoustophoresis-assisted fluid jet polishing process

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.052

Anomitra Saha , Abhijit Dhamanekar , N. Arunachalam , S.V. Diwakar

The current work presents the numerical simulations of a novel acoustophoresis-assisted Fluid Jet Polishing (FJP) process. The underlying principle of the new technique involves migrating abrasive particles to desired locations (pressure nodes) within the jet using standing acoustic waves. The migration of particles occurs on account of the radiation force arising from the difference in the acoustic impedance of the particles and the carrier fluid. In the present work, we analyze the proposed FJP procedure using multiphase simulations involving a combination of Eulerian and Lagrangian approaches. The influence of acoustophoresis on circular and square cross-sectioned nozzles has been primarily evaluated. Though the pressure nodes in circular nozzles can help achieve precise annular erosion, they do not alter the inhomogeneous W-shaped erosion profile usually observed in conventional FJP systems. In contrast, the acoustic forcing in square cross-section nozzles propels the particles towards the jet axis, thereby manifesting a U-shaped erosion profile for specific operating conditions that have been identified via a systematic analysis. Such particle focussing/redistribution capabilities provide a unique means of controlling erosion, removing machining inhomogeneity, enhancing the material removal rate, and pattern formation during the FJP process.

{"title":"Numerical simulations of an acoustophoresis-assisted fluid jet polishing process","authors":"Anomitra Saha , Abhijit Dhamanekar , N. Arunachalam , S.V. Diwakar","doi":"10.1016/j.jmapro.2024.12.052","DOIUrl":"10.1016/j.jmapro.2024.12.052","url":null,"abstract":"<div><div>The current work presents the numerical simulations of a novel acoustophoresis-assisted Fluid Jet Polishing (FJP) process. The underlying principle of the new technique involves migrating abrasive particles to desired locations (pressure nodes) within the jet using standing acoustic waves. The migration of particles occurs on account of the radiation force arising from the difference in the acoustic impedance of the particles and the carrier fluid. In the present work, we analyze the proposed FJP procedure using multiphase simulations involving a combination of Eulerian and Lagrangian approaches. The influence of acoustophoresis on circular and square cross-sectioned nozzles has been primarily evaluated. Though the pressure nodes in circular nozzles can help achieve precise annular erosion, they do not alter the inhomogeneous W-shaped erosion profile usually observed in conventional FJP systems. In contrast, the acoustic forcing in square cross-section nozzles propels the particles towards the jet axis, thereby manifesting a U-shaped erosion profile for specific operating conditions that have been identified via a systematic analysis. Such particle focussing/redistribution capabilities provide a unique means of controlling erosion, removing machining inhomogeneity, enhancing the material removal rate, and pattern formation during the FJP process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 1034-1056"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132045","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 and experimental analysis for the effect of oil mist flow characteristics on the penetration and lubrication performance in MQL milling

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.080

Guochao Qiao , Xiaoyang Xiong , Jie Yang , Dong Zhen , Fujiang Zhang , Yongjie Wei

The penetration of oil mist and its lubrication capabilities in Minimum Quantity Lubrication (MQL) are closely related to the flow field characteristics. However, due to the lack of comprehensive studies on the nozzle atomization performance and the distribution characteristics of the flow field in the cutting zone, an in-depth understanding of the lubrication mechanism of MQL remains a challenge. This study simulated the single-nozzle atomized flow field and flow field distribution characteristics of the dual-nozzle MQL milling using the computational fluid dynamics (CFD) technique. The effects of air pressure and flow rate on the flow field characteristics, such as droplet diameter, number of droplets, flow velocity, and volume fraction, were analyzed. Additionally, the effects of nozzle distance and incidence angle on the flow field distribution characteristics around the milling cutter were also examined. By combining laser particle size analysis with MQL milling experiments, the optimal conditions for lubricant penetration into the cutting zone were identified, revealing the low-pressure vortex lubrication mechanism of MQL. The results indicate that the optimal conditions for oil mist delivery are air pressure of 0.4–0.5 MPa, flow rate of 40 mL/h, and droplet diameter of 5–9 μm. Furthermore, the cutting performance of MQL reaches its best when the nozzle distance and incidence angle are 35 mm and 30°, respectively. The findings of this study are significant for understanding the lubrication mechanism and enhancing the cutting performance of MQL.

{"title":"Numerical and experimental analysis for the effect of oil mist flow characteristics on the penetration and lubrication performance in MQL milling","authors":"Guochao Qiao , Xiaoyang Xiong , Jie Yang , Dong Zhen , Fujiang Zhang , Yongjie Wei","doi":"10.1016/j.jmapro.2024.12.080","DOIUrl":"10.1016/j.jmapro.2024.12.080","url":null,"abstract":"<div><div>The penetration of oil mist and its lubrication capabilities in Minimum Quantity Lubrication (MQL) are closely related to the flow field characteristics. However, due to the lack of comprehensive studies on the nozzle atomization performance and the distribution characteristics of the flow field in the cutting zone, an in-depth understanding of the lubrication mechanism of MQL remains a challenge. This study simulated the single-nozzle atomized flow field and flow field distribution characteristics of the dual-nozzle MQL milling using the computational fluid dynamics (CFD) technique. The effects of air pressure and flow rate on the flow field characteristics, such as droplet diameter, number of droplets, flow velocity, and volume fraction, were analyzed. Additionally, the effects of nozzle distance and incidence angle on the flow field distribution characteristics around the milling cutter were also examined. By combining laser particle size analysis with MQL milling experiments, the optimal conditions for lubricant penetration into the cutting zone were identified, revealing the low-pressure vortex lubrication mechanism of MQL. The results indicate that the optimal conditions for oil mist delivery are air pressure of 0.4–0.5 MPa, flow rate of 40 mL/h, and droplet diameter of 5–9 μm. Furthermore, the cutting performance of MQL reaches its best when the nozzle distance and incidence angle are 35 mm and 30°, respectively. The findings of this study are significant for understanding the lubrication mechanism and enhancing the cutting performance of MQL.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 603-618"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131929","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

Residual stress and subsurface damage prediction in tungsten heavy alloy face grinding

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.038

Gan Li, Jinbo Liu, Hao Wang, Zhigang Dong, Renke Kang, Yan Bao

Residual stress distribution and subsurface damage (SSD) play a crucial role in the fatigue performance and accuracy maintenance of the parts. As a typical two-phase difficult-to-machine material, the two-phase microstructure evolution and damage mechanism of tungsten heavy alloy (WHA) under face grinding have not been fully understood. In this paper, a flow stress model considering grain orientation, grain size effect and dynamic recrystallization effect of WHA was established, and the residual stresses formation during the WHA grinding process was predicted based on this model. A calculation method for determining the depth of the SSD layer based on grain boundary curvature is also proposed, and the relationship between microstructure evolution, formation of SSD, and residual stress under face grinding conditions is discussed. Finally, the proposed model was experimentally verified. The experimental results show that the residual stress on the surface of WHA face grinding is compressive stress, and the value is almost three times larger than that of the conventional grinding method. The results are consistent with the trend of the model, and the prediction error of the residual stress prediction model is about 12 %. The change rule of residual stress and SSD depth with grinding parameters is summarized, which provides a reference for realizing high-precision and high surface integrity machining of WHA and other difficult-to-machine composites.

{"title":"Residual stress and subsurface damage prediction in tungsten heavy alloy face grinding","authors":"Gan Li, Jinbo Liu, Hao Wang, Zhigang Dong, Renke Kang, Yan Bao","doi":"10.1016/j.jmapro.2024.12.038","DOIUrl":"10.1016/j.jmapro.2024.12.038","url":null,"abstract":"<div><div>Residual stress distribution and subsurface damage (SSD) play a crucial role in the fatigue performance and accuracy maintenance of the parts. As a typical two-phase difficult-to-machine material, the two-phase microstructure evolution and damage mechanism of tungsten heavy alloy (WHA) under face grinding have not been fully understood. In this paper, a flow stress model considering grain orientation, grain size effect and dynamic recrystallization effect of WHA was established, and the residual stresses formation during the WHA grinding process was predicted based on this model. A calculation method for determining the depth of the SSD layer based on grain boundary curvature is also proposed, and the relationship between microstructure evolution, formation of SSD, and residual stress under face grinding conditions is discussed. Finally, the proposed model was experimentally verified. The experimental results show that the residual stress on the surface of WHA face grinding is compressive stress, and the value is almost three times larger than that of the conventional grinding method. The results are consistent with the trend of the model, and the prediction error of the residual stress prediction model is about 12 %. The change rule of residual stress and SSD depth with grinding parameters is summarized, which provides a reference for realizing high-precision and high surface integrity machining of WHA and other difficult-to-machine composites.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 175-192"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132265","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

Improvement of directional anisotropy and its impact on surface and mechanical properties of a rib-on-plate structure fabricated through friction stir processing of additively manufactured friction stir surfaced structure

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.022

Souvik Karmakar, Surjya Kanta Pal

Maintaining isotropic properties is an essential need for large-scale metal Additive Manufacturing (AM). This paper presents a novel hybrid technique for fabricating rib-on-plate structures using Friction Stir Surfacing (FSS) and sidewall-assisted Friction Stir Processing (FSP). A reasonably high joint efficiency (

η_{joint}

) of 96.60 % indicates a higher utilization of FSS-based deposition volume in manufacturing metal panels. Material consolidation via FSP exerted a dominant influence on reducing the heterogeneous mechanical properties of the multi-layer FSSed structure, making it suitable for cyclic loading applications. Additionally, the structure achieved an improved tensile strength (15.97 %) than the FSSed structure. The absence of interlayer separation in the tensile fracture surface morphology confirmed the structural integrity of the end product. Microhardness and Electron Backscatter Diffraction (EBSD) analysis revealed an enhancement in interlayer quality, as evidenced by the lack of non-jointed surfaces and a narrow zone of microstructural variations in post-processed structure. The detailed investigation demonstrated that the FSP operation following four FSS-based depositions could be a wise decision for preserving the balance between the overall defect volume and process cycle time.

{"title":"Improvement of directional anisotropy and its impact on surface and mechanical properties of a rib-on-plate structure fabricated through friction stir processing of additively manufactured friction stir surfaced structure","authors":"Souvik Karmakar, Surjya Kanta Pal","doi":"10.1016/j.jmapro.2024.12.022","DOIUrl":"10.1016/j.jmapro.2024.12.022","url":null,"abstract":"<div><div>Maintaining isotropic properties is an essential need for large-scale metal Additive Manufacturing (AM). This paper presents a novel hybrid technique for fabricating rib-on-plate structures using Friction Stir Surfacing (FSS) and sidewall-assisted Friction Stir Processing (FSP). A reasonably high joint efficiency (<span><math><msub><mi>η</mi><mi>joint</mi></msub></math></span>) of 96.60 % indicates a higher utilization of FSS-based deposition volume in manufacturing metal panels. Material consolidation via FSP exerted a dominant influence on reducing the heterogeneous mechanical properties of the multi-layer FSSed structure, making it suitable for cyclic loading applications. Additionally, the structure achieved an improved tensile strength (15.97 %) than the FSSed structure. The absence of interlayer separation in the tensile fracture surface morphology confirmed the structural integrity of the end product. Microhardness and Electron Backscatter Diffraction (EBSD) analysis revealed an enhancement in interlayer quality, as evidenced by the lack of non-jointed surfaces and a narrow zone of microstructural variations in post-processed structure. The detailed investigation demonstrated that the FSP operation following four FSS-based depositions could be a wise decision for preserving the balance between the overall defect volume and process cycle time.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 90-106"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132269","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

Magnetic field assisted micro-milling of selective laser melted titanium alloy

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.069

Muhammad Rehan , Danish Tahir , Ping Guo , Wai Sze Yip , Sandy Suet To

Selective Laser Melting (SLM) is one of the additive manufacturing technologies for producing titanium alloy parts. Following SLM, micro-milling is critical to achieving good surface quality of the fabricated part. This study examines the impact of a magnetic field on the micro-milling of SLM Ti6Al4V, aligning with existing theories that suggest its advantages. Comparative experiments demonstrate a 22 % reduction in average surface roughness when using a magnetic field. The study also explores the transverse distribution of surface roughness in magnetic field-assisted micro-milling. SEM images confirm fewer surface defects, such as welded chips, material side flow, deep feed marks, and microparticles. Additionally, the application of a magnetic field significantly reduces tool wear, including built-up edge (BUE), micro-chipping, and adhesive wear. These findings offer valuable insights for employing magnetic fields in the micro-milling of additively manufactured parts.

引用次数: 0

Study on the mechanism of inhibitory effect of composite micro-textures on derivative cutting

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2025.01.004

Quan Wan, Jikai Yi, Xueyuan Tang, Xiaoyu Hu, Sicheng Zhang, Shucai Yang

It is found after years of research that micro-textured tools have a wide range of application prospects due to their ability to improve the cutting performance effectively. The derivative chips generated during the derivative cutting by micro-textured tools are primarily responsible for the micro-texture failure. In this work, a multi-scale composite micro-texture (MSC-MT) is mathematically modeled for exploring its mechanism of inhibiting derivative cutting. The feasibility of the MSC-MT configuration to inhibit the derivative cutting was verified through the simulation of multi-scale cutting, spanning from micro to macro cutting conditions. The performance of the MSC-MT configured tool was evaluated in comparison to that of the pit-type micro-texture (PT-MT) configured tool by conducting a series of comparative experiments, which included the comparison of life and two-dimensional orthogonal cutting. The formation of derivative chips was also monitored and recorded by high-speed photography. Derivative chips were generated in the PT-MT configuration upon diverting the chips under the action of the chip diversion point, while the back-slope of the MSC-MT configuration allowed the chips to flow directly out of the micro-texture.

{"title":"Study on the mechanism of inhibitory effect of composite micro-textures on derivative cutting","authors":"Quan Wan, Jikai Yi, Xueyuan Tang, Xiaoyu Hu, Sicheng Zhang, Shucai Yang","doi":"10.1016/j.jmapro.2025.01.004","DOIUrl":"10.1016/j.jmapro.2025.01.004","url":null,"abstract":"<div><div>It is found after years of research that micro-textured tools have a wide range of application prospects due to their ability to improve the cutting performance effectively. The derivative chips generated during the derivative cutting by micro-textured tools are primarily responsible for the micro-texture failure. In this work, a multi-scale composite micro-texture (MSC-MT) is mathematically modeled for exploring its mechanism of inhibiting derivative cutting. The feasibility of the MSC-MT configuration to inhibit the derivative cutting was verified through the simulation of multi-scale cutting, spanning from micro to macro cutting conditions. The performance of the MSC-MT configured tool was evaluated in comparison to that of the pit-type micro-texture (PT-MT) configured tool by conducting a series of comparative experiments, which included the comparison of life and two-dimensional orthogonal cutting. The formation of derivative chips was also monitored and recorded by high-speed photography. Derivative chips were generated in the PT-MT configuration upon diverting the chips under the action of the chip diversion point, while the back-slope of the MSC-MT configuration allowed the chips to flow directly out of the micro-texture.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 633-647"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131931","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

Current trends and future prospects of electrodeposition technology for the preparation of heterogeneous structural materials

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.026

Xiaohong Yang , Xinmin Zhang , Pingmei Ming , Youping Xiao , Xiaoyi Guo

Heterogeneous structural materials (HSMs) are well known for their excellent mechanical properties, such as high strength, plasticity, and fracture toughness, which are far superior to homogeneous materials. Consequently, they find extensive applications in various fields, including mechanics, electronics, optics, magnetism, chemistry, and biology. These exceptional properties primarily stem from the synergistic effects arising from the interactions between their constituent components, encompassing stress/strain gradients, geometrically necessary dislocations, and unique interfacial behaviors. Numerous investigations have been conducted on the preparation of HSMs. This study aims to summarize their advantages and fundamental principles. We categorized the HSMs, emphasizing their design, optimization of mechanical properties, physical and chemical characterization, and the pivotal role of electrodeposition techniques in the preparation process. In addition, we forecast future trends and identify key research challenges in the electrodeposition of HSMs.

{"title":"Current trends and future prospects of electrodeposition technology for the preparation of heterogeneous structural materials","authors":"Xiaohong Yang , Xinmin Zhang , Pingmei Ming , Youping Xiao , Xiaoyi Guo","doi":"10.1016/j.jmapro.2024.12.026","DOIUrl":"10.1016/j.jmapro.2024.12.026","url":null,"abstract":"<div><div>Heterogeneous structural materials (HSMs) are well known for their excellent mechanical properties, such as high strength, plasticity, and fracture toughness, which are far superior to homogeneous materials. Consequently, they find extensive applications in various fields, including mechanics, electronics, optics, magnetism, chemistry, and biology. These exceptional properties primarily stem from the synergistic effects arising from the interactions between their constituent components, encompassing stress/strain gradients, geometrically necessary dislocations, and unique interfacial behaviors. Numerous investigations have been conducted on the preparation of HSMs. This study aims to summarize their advantages and fundamental principles. We categorized the HSMs, emphasizing their design, optimization of mechanical properties, physical and chemical characterization, and the pivotal role of electrodeposition techniques in the preparation process. In addition, we forecast future trends and identify key research challenges in the electrodeposition of HSMs.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 29-59"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132002","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

Study on the formation of anfractuous interlocking interface in laser shock of molten pool

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.032

Yi He , Zhe Zhao , Shusen Zhao , Yaowu Hu

A method utilizing dual molten pool and laser shock in hybrid additive manufacturing was employed to form an anfractuous interlocking interface, thereby enhancing the joining performance of dissimilar metals. Leveraging on the substantial difference in melting points between the two metals, the Ti6Al4V wire (melting point ~1668 °C) was partially melted using a continuous wave laser in directed energy deposition technology, while the aluminum alloy substrate (melting point ~635 °C) underwent partial melting via heat conduction. This process resulted in the creation of a dual molten pool area comprising liquid wire, solid wire, and liquid substrate. Additionally, applying a laser shock simultaneously inducing oscillation and promoting heat transfer within molten pool. This process effectively eliminated pore defects and facilitated the formation of an anfractuous interlocking interface. The molten pool and anfractuous interlocking interface were evaluated under varying laser shock energies. At 2 J, the joint strength of the AlTi achieved 422.6 MPa, with a number of pore defects decreasing by approximately 63.23 % and microhardness increasing by 9.20 %. Furthermore, this method has enlightening significance for the joining of dissimilar materials and serves as a valuable reference for dissimilar welding, providing a new technology for laser additive manufacturing.

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