Journal of Manufacturing Processes最新文献

{"title":"Design and performance evaluation of a directional internal-cooling grooved grinding wheel with optimized coolant supply structure","authors":"Ruitao Peng ,&nbsp;Weisen Yan ,&nbsp;Linfeng Zhao ,&nbsp;Meiliang Chen ,&nbsp;Xiangwu Xiao","doi":"10.1016/j.jmapro.2025.02.059","DOIUrl":"10.1016/j.jmapro.2025.02.059","url":null,"abstract":"<div><div>To enhance thermal management and optimize coolant efficiency in the peripheral grinding of superalloys, a novel internal-cooling grinding wheel incorporating a directional structural design was developed. The pressurized coolant is delivered to the grinding zone via an integrated system comprising the pipework, tool holder, and symmetrically arranged manifold ports. This symmetrical manifold port configuration enables precise and efficient control of coolant distribution. Through optimization of the symmetrical manifold port positioning using Computational Fluid Dynamics (CFD) simulations, the internal flow field of the grinding wheel was enhanced, resulting in increased outlet flow rates, improved distribution uniformity, and higher effective flow rates. Additionally, cubic boron nitride (CBN) abrasive rings featuring varying groove structures were fabricated via an electroplating process. A vertical peripheral grinding test platform incorporating directional internal cooling was developed to perform grinding experiments on superalloys. The experimental results demonstrated that, compared to conventional flood cooling, directional internal cooling achieved a reduction in grinding temperature by up to 16.9%, a decrease in surface roughness by up to 14.8%, and a reduction in workpiece surface microhardness by up to 6.11%, under equivalent coolant flow rate conditions. Among the tested configurations, the parallel slot design under directional internal cooling yielded the lowest grinding temperature and minimal surface microhardness, exhibiting reductions of 22.7% and 7.12%, respectively, compared to the non-slotted structure. This performance surpassed that of the diagonal slot, V-shape slot, and non-slotted configurations. However, a marginal degradation in surface morphology was observed for the slotted structures relative to the non-slotted design.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 155-168"},"PeriodicalIF":6.1,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143528705","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}

{"title":"Flash regeneration of superhydrophilicity and antifog performance of laser induced molybdenum based micro-nano structures by flame treatment","authors":"Chengling Liu,&nbsp;Xiaolong Fang,&nbsp;Xiaojie Chen,&nbsp;Xiaowen Qi,&nbsp;Chao Teng,&nbsp;Xinyi Xie,&nbsp;Youfu Wang,&nbsp;Guixia Lu,&nbsp;Longze Chen,&nbsp;Longfei Mi,&nbsp;Hongtao Cui","doi":"10.1016/j.jmapro.2025.02.079","DOIUrl":"10.1016/j.jmapro.2025.02.079","url":null,"abstract":"<div><div>In this study, a low cost laser marker fast ablation of molybdenum (Mo) coated glass substrate was adopted to fabricate superhydrophilic micro-nano structure. A hierarchical micro-nano structure with quasi-periodical hillock-hollow micron structure and widely distributed nanoparticles were shown on the treated surface, which resulted in a contact angle of 0°. The treated glass showcased remarkable antifog performance without apparent degradation for over 12 months, which was an impressive record free of apparent degradation. It also exhibited apparent antifog performance with increased water contact angle (WCA) to 5.5° after two weeks salt spray test, such low WCA and impressive antifog performance after such long salt spray test has not been reported before. However, the sample surface exhibited a marked decline in superhydrophilicity and antifog performance after over 15 months storage in the laboratory, which was attributed to the deposition of organic pollutants in the ambient. Thermal annealing at 400 °C for 1 h partially restored the antifog and superhydrophilic properties, reducing the contact angle to 7.4°. Remarkably, a one-second flame treatment fully restored the superhydrophilicity and antifog properties, which induced surface chemistry redistribution and was not reported before. Additionally, the treated glass demonstrated self-cleaning properties and enhanced broadband transmission. This brief and straightforward treatment highlights the potential of laser-ablated glass for a wide range of practical applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 169-180"},"PeriodicalIF":6.1,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143529350","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}

{"title":"Generative adversarial networks (GAN) model for dynamically adjusted weld pool image toward human-based model predictive control (MPC)","authors":"Tianpu Li ,&nbsp;Yue Cao ,&nbsp;Qiang Ye ,&nbsp;YuMing Zhang","doi":"10.1016/j.jmapro.2025.02.053","DOIUrl":"10.1016/j.jmapro.2025.02.053","url":null,"abstract":"<div><div>Gas Metal Arc Welding (GMAW) is a critical industrial technique known for its high productivity, flexibility, and adaptability to automation. Despite the significant advancements in robotic welding, challenges remain in fully automating the arc welding process, particularly due to the complex dynamics of the weld pool associated with GMAW. A human-robot collaborative (HRC) system where humans operate robots may conveniently provide the needed adaptive control to the complex GMAW. While in conventional HRC systems humans receive process feedback to make adaptive adjustments, we propose provide humans with predictive future feedback to further ease the human decision and reduce the needed skills/trainings. To this end, this study explores the integration of deep learning models, specifically Generative Adversarial Networks (GANs) combined with Gated Recurrent Units (GRUs), to model and predict the dynamic behavior of the weld pool during GMAW. By leveraging time-series data of torch movement and corresponding weld pool images, the proposed GRU-GAN model generates high-fidelity weld pool images, capturing the intricate relationship between speed variations and weld pool morphology. Through extensive experimentation, including the design of an acceptable Encoder-Decoder structure for the GAN, we demonstrate that incorporating both temporal and speed sequence information significantly enhances the model's predictive capabilities. The findings validate the hypothesis that dynamic torch speed adjustments, akin to those performed by skilled human welders, can be effectively modeled to improve the quality of automated welding processes. Future work will be devoted to human-based model predictive control (MPC) in an HRC environment.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 210-221"},"PeriodicalIF":6.1,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552412","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}

{"title":"Study on removal mechanism and edge breakage of C/C composites in orthogonal cutting","authors":"Wengang Liu ,&nbsp;Chenwei Shan ,&nbsp;Fangchao Jia ,&nbsp;Ziwen Xia ,&nbsp;Menghua Zhang","doi":"10.1016/j.jmapro.2025.02.064","DOIUrl":"10.1016/j.jmapro.2025.02.064","url":null,"abstract":"<div><div>C_MP/C composites reinforced with mesophase pitch-based carbon fibers (MPCFs) have high Young's modulus and ultrahigh thermal conductivity, making them promising heat-dissipative materials with significant application potential. However, up to now, the cutting mechanism of C_MP/C composites has not been reported. In this study, orthogonal cutting experiments with variable cutting depths were designed for C_MP/C composites to obtain the critical cutting depths between micro-brittle and macro-brittle removal modes. The cutting removal mechanisms as well as different morphologies and subsurface damage were analyzed for three cutting directions. Experimental results indicated that the critical cutting depth was 56 μm for the cutting direction perpendicular to the fiber, and 31 μm for the cutting direction along the fiber. MPCFs was more prone to laminar brittle fracture, resulting in rougher fracture surfaces with low subsurface fiber damage but significant damage to the fiber-matrix interface. In contrast, cutting parallel to the fibers caused greater surface and subsurface damage, exhibiting macro-brittle removal mode without a critical cutting depth. Finally, based on the flexural mechanism and elastic beam bending theory, the reason why the edge position of C_MP/C composites was more prone to damage was explained. The intrinsic mechanism of damage formation was further revealed and suggestions were proposed to control edge brakeage.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 222-236"},"PeriodicalIF":6.1,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552413","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}

{"title":"Implicit feedrate planning method for high-efficient parametric CNC interpolation with multi-constraints","authors":"Shisheng Lv ,&nbsp;Qiang Liu ,&nbsp;Liuquan Wang ,&nbsp;Pengpeng Sun ,&nbsp;Jian Wang","doi":"10.1016/j.jmapro.2025.02.060","DOIUrl":"10.1016/j.jmapro.2025.02.060","url":null,"abstract":"<div><div>Spline-based parametric interpolation has been widely applied in CNC systems. However, conventional feedrate planning which focuses on scheduling the tool tip feedrate profile, presents several challenges. These include difficulties in managing 5-axis trajectories with fixed tool tips due to zero feedrate, and a complex interpolation process that requires calculating the arc-length increment d<em>s</em> and parameter increment d<em>u</em>, which may lead to feedrate fluctuations. To overcome these challenges, this paper proposes a novel implicit feedrate planning method that directly establishes the relationship between the trajectory parameter <em>u</em> and machining time <em>t</em>, with the feedrate implicitly represented in the <em>u</em>−<em>t</em> profile. This allows the CNC to compute the parameter increment d<em>u</em> based on a time step d<em>t</em>, without the calculation of arc-length and significantly simplifying the interpolation process, thus enhancing efficiency. Moreover, a new characteristic of B-spline, the Local Modification Scheme of the First Derivative, is introduced, which enables iterative adjustments to the <em>u</em>−<em>t</em> curve to achieve near time-optimal feedrate while adhering to multiple constraints. Simulation and experimental results demonstrate that the proposed method achieves a superior balance between computational efficiency and machining time compared to other iterative-based or dynamic look-ahead feedrate planning methods. Moreover, it improves interpolation efficiency by approximately 45 % compared to explicit feedrate planning methods.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 193-209"},"PeriodicalIF":6.1,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552411","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}

{"title":"Hierarchical heterogeneous microstructure for enhanced wear resistance of CoCrFeMnNi high-entropy alloy coatings via in-situ rolling assisted laser cladding","authors":"Hao Liu ,&nbsp;Baochen Wang ,&nbsp;Peijian Chen ,&nbsp;Dali Li ,&nbsp;Jingbin Hao ,&nbsp;Haifeng Yang ,&nbsp;Xiuli He ,&nbsp;Gang Yu","doi":"10.1016/j.jmapro.2025.02.066","DOIUrl":"10.1016/j.jmapro.2025.02.066","url":null,"abstract":"<div><div>Heterogeneous high-entropy alloys (HEAs) are promising materials due to their excellent mechanical properties. In this study, hierarchical heterostructures were introduced into CoCrFeMnNi HEA via an in-situ rolling (ISR) assisted laser cladding (LC) process. The microstructural evolution and tribological behavior of the ISR-assisted LC coating were investigated. Results indicate that porosity and surface roughness are significantly reduced, as the plastic flow during ISR-assisted LC closes pore and fills the surface valley. ISR induces a gradient distribution of dislocation density and grain size along the depth direction, and the thermal effect of subsequent laser track deposition leads to a tilted-strip distribution of grain size and geometrically necessary dislocations (GNDs) along the overlapping direction. During ISR-assisted LC process, the combined effects of deformation and recrystallization reduce the average grain size from 93.84 μm to 32.47 μm, decrease the texture intensity from 9.83 to 4.23, and extend the strain depth to 950 μm. The reduction in porosity, increase in microhardness, and hierarchical heterostructure strengthening collectively enhance the wear resistance of the ISR-assisted LC coating. The volume wear rate reduces significantly from 1.740 × 10⁻⁴ mm³·N⁻¹·m⁻¹ to 0.133 × 10⁻⁴ mm³·N⁻¹·m⁻¹. This study provides a novel approach for the design of wear-resistant HEA coatings.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 105-120"},"PeriodicalIF":6.1,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143519585","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}

{"title":"Investigation on the five-axis stability prediction of rigid and flexible workpiece","authors":"Boling Yan ,&nbsp;Chunxia Zhu ,&nbsp;Lida Zhu","doi":"10.1016/j.jmapro.2025.02.072","DOIUrl":"10.1016/j.jmapro.2025.02.072","url":null,"abstract":"<div><div>Milling chatter is harmful to the machine tool and product, especially for workpiece with weak stiffness. For five-axis milling, due to the complex tool-workpiece engagement and relative spatial position, the prediction and mechanism analysis of chatter are more difficult. In this work, five-axis milling dynamics was investigated. Firstly, the dynamic milling model of rigid and flexible Workpiece were built respectively. Secondly, the cutter-workpiece engagement (CWE) was modeled, and together with numerical method, the delayed difference equation (DDE) for flexible workpiece considering modal coordinate (z axis of FCN coordinate) were built and solved. The prediction results were examined by cutting test, and showed good agreement with the predicted SLD. This paper investigates the critical issues related to the machining stability of thin-walled parts in five-axis milling, including the CWE model, the derivation of regenerative forces, and the development of the dynamic model, offering a unique perspective to understand five-axis milling chatter.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 132-154"},"PeriodicalIF":6.1,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143519582","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}

{"title":"Printing path induced temperature history and interfacial properties of 3D printed continuous nature fiber reinforced polypropylene composites","authors":"Xiongbing Li ,&nbsp;Yuxuan Liu ,&nbsp;Shixian Li ,&nbsp;Kui Wang ,&nbsp;J.P.M. Correia ,&nbsp;Said Ahzi","doi":"10.1016/j.jmapro.2025.02.054","DOIUrl":"10.1016/j.jmapro.2025.02.054","url":null,"abstract":"<div><div>The mechanical properties of continuous ramie fiber reinforced polypropylene (CRFRPP) are constrained by limited interlayer adhesion, which is dependent on the temperature history and attributed to the weak pressure in the fused filament fabrication (FFF) process. To study the relationship between the temperature history and interlayer performance of the CRFRPP. The characteristic of temperature history for the concentric, zigzag 1, and zigzag 2 printing path were investigated through in-situ monitoring using an infrared camera. The interfacial performance of specimen with different printing paths was studied through T-peel test, and morphological properties of the specimens before and after T-peel test were investigated. Finally, the mechanical properties of specimens with different printing paths were further investigated through three-point bending tests. The results showed that specimens with the concentric path presented the longest effective welding time compared to zigzag 1 and zigzag 2 specimens, attributed to the different thermal behaviors in sublayer. The interfacial adhesive force of the concentric specimen was 103 % higher than that of zigzag 2, and zigzag 1 had a 51 % higher interfacial adhesive force than zigzag 2 after the T-peel test. The morphological analysis revealed that concentric specimens presented fewer defects in cross-section and irregular fracture surface compared to other printing paths, in the current ranges of study. The superior interlayer properties of concentric specimens resulted in better flexural strength and flexural modulus, with failure modes characterized by breakages of the fiber and matrix.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 121-131"},"PeriodicalIF":6.1,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143519586","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}

{"title":"Designing high-strength and low-deformation diffusion-bonded 5A06 joints via spark plasma sintering and heat treatment","authors":"Tong Wu ,&nbsp;Rui Xu ,&nbsp;Hang Lu ,&nbsp;Yuan Gao ,&nbsp;Yongjun Li ,&nbsp;Kun Fang ,&nbsp;Fugang Lu ,&nbsp;Ce Wang ,&nbsp;Panpan Lin ,&nbsp;Tiesong Lin ,&nbsp;Peng He","doi":"10.1016/j.jmapro.2025.02.076","DOIUrl":"10.1016/j.jmapro.2025.02.076","url":null,"abstract":"<div><div>This study explores how to achieve high-strength and low-deformation rate diffusion-bonded joints. Herein, a 5A06 joint with 193 MPa tensile strength and 0.99 % deformation rate was successfully fabricated by spark plasma sintering diffusion bonding (SPSDB) and pulsed current. Meanwhile, the dynamic recrystallization (DRX) behavior in 5A06 during SPSDB was first systematically investigated by electron back-scattered diffraction (EBSD) and transmission electron microscopy (TEM). The results revealed that continuous DRX (CDRX) grains were formed near the bonding interface during SPSDB.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 93-104"},"PeriodicalIF":6.1,"publicationDate":"2025-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143519584","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}

{"title":"A deep neural network approach to predict dimensional accuracy of thin-walled tubes in backward flow forming plasticity process","authors":"Acar Can Kocabıçak ,&nbsp;Can Wang ,&nbsp;Sutao Han ,&nbsp;H. Nguyen-Xuan ,&nbsp;Gregor Kosec ,&nbsp;Lihua Wang ,&nbsp;Magd Abdel Wahab","doi":"10.1016/j.jmapro.2025.02.044","DOIUrl":"10.1016/j.jmapro.2025.02.044","url":null,"abstract":"<div><div>Flow forming is a cold forming method that significantly enhances the mechanical properties of the workpiece. The main goal of this study is to perform a new prediction method for flow formed part dimensional accuracy based on Deep Neural Network (DNN) and Finite Element Analysis (FEA). The DIN 1.7220 steel is generated in this work because it is used in the automotive and aerospace industries due to its high fatigue strength and abrasion resistance. The selection of flow forming parameters, including the feed rate and spindle speed, is essential to guarantee that the dimensional specifications of the component design are fulfilled. Potential defects, such as material build-up, bulge, and diametrical growth, are predicted using FEA. This research addresses the limited literature on flow-forming operations, particularly the absence of studies integrating DNN with the flow-forming process to compare dimensional accuracy against FEA. This methodological innovation aims at leveraging Machine Learning (ML) to enhance precision in predicting outcomes based on critical parameters such as feed rate and mandrel speed, directly influencing wall thickness variation and mean inner diameter of the parts in a fixed reduction ratio and roller dimensions. Although variable hidden layers and neurons are generated, the most accurate results are found in three hidden layers with eight neurons compared to FEA outcomes. Rectified Linear Unit (ReLU) activation function is used in the model. Based on this DNN model configuration, the overall error in wall thickness and mean inner diameter is less than 0.01 % across all five groups. The Root Mean Square (RMS) error is used to show the differences between wall thickness and mean inner diameters predicted by the DNN model and the actual values. The minimum wall thickness RMS error among all the groups is 0.013, and the lowest mean inner diameter is found to be 0.001. A comparative analysis demonstrates that the newly proposed DNN method can accurately predict the final dimensions of flow formed tubes with low computational costs. The predictive precision and reliability are significantly enhanced compared to the theoretical framework based on FEA results. The integration of DNN with FEA enhances dimensional predictions, offering high accurate results while reducing computation time.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 59-80"},"PeriodicalIF":6.1,"publicationDate":"2025-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143519583","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}