Pub Date : 2025-01-31DOI: 10.1016/j.jmapro.2024.12.070
Shadab Ahmad , Yebing Tian , Kunal Arora
Magnetic abrasive finishing (MAF) has emerged as a leading nano-finishing technology, offering precision and versatility across diverse materials. This review comprehensively examines MAF principles, classification, modeling-simulations, optimization techniques, and hybrid processes. Extensive experimental studies on surface finishing across varied materials and geometries are analyzed, highlighting influential process parameters and the role of magnetic abrasives. Various types and preparation methods of magnetic abrasives are discussed, along with the significance of magnetic tool geometry and sources. Modeling simulations addressing material removal, surface roughness, and temperature prediction are explored. The review concludes with discussions on applications, challenges, and future research avenues, emphasizing MAF's value in addressing complex parts and geometries. Recommendations include integrating standardization, automation, and innovative strategies to amplify MAF's relevance in mass production scenarios. Key findings reveal MAF's precision and versatility in achieving nano-level surface finishes, with recommendations for optimized magnetic abrasive utilization. Challenges in high-accuracy component mass production are identified, along with strategies to enhance efficiency and effectiveness in MAF applications. Overall, this review provides valuable insights for researchers, practitioners, and academicians seeking comprehensive knowledge of MAF.
{"title":"Magnetic abrasive finishing: Innovations and possibilities","authors":"Shadab Ahmad , Yebing Tian , Kunal Arora","doi":"10.1016/j.jmapro.2024.12.070","DOIUrl":"10.1016/j.jmapro.2024.12.070","url":null,"abstract":"<div><div>Magnetic abrasive finishing (MAF) has emerged as a leading nano-finishing technology, offering precision and versatility across diverse materials. This review comprehensively examines MAF principles, classification, modeling-simulations, optimization techniques, and hybrid processes. Extensive experimental studies on surface finishing across varied materials and geometries are analyzed, highlighting influential process parameters and the role of magnetic abrasives. Various types and preparation methods of magnetic abrasives are discussed, along with the significance of magnetic tool geometry and sources. Modeling simulations addressing material removal, surface roughness, and temperature prediction are explored. The review concludes with discussions on applications, challenges, and future research avenues, emphasizing MAF's value in addressing complex parts and geometries. Recommendations include integrating standardization, automation, and innovative strategies to amplify MAF's relevance in mass production scenarios. Key findings reveal MAF's precision and versatility in achieving nano-level surface finishes, with recommendations for optimized magnetic abrasive utilization. Challenges in high-accuracy component mass production are identified, along with strategies to enhance efficiency and effectiveness in MAF applications. Overall, this review provides valuable insights for researchers, practitioners, and academicians seeking comprehensive knowledge of MAF.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 299-336"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132196","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 : 2025-01-31DOI: 10.1016/j.jmapro.2024.12.040
Fei Su, Xinzhe Zhang, Yan Che
Kevlar fiber reinforced plastic (KFRP) is widely used in military industry and aircraft field. Traditional mechanical drilling often leads to defects such as delamination and fiber drawing. The processing technology significantly influences the defects in hole drilling. In this paper, given the high thermal sensitivity of KFRP, a rotary cutting process with induction heating of the tool is proposed, and a corresponding tool structure is designed. Upon application of heat to the tool, the highest temperature of the tool tip is transferred instantaneously to the workpiece material in the cutting area. As the temperature of the material rises, its mechanical properties decline. There is a significant force-heat concentration effect in the advance of the tool. The application of force and heat results in a reduction of thermal damage in the cutting zone, accompanied by a notable decrease in the formation of fiber drawing and delamination. The best surface quality of the hole is achieved when the feed speed Vf = 210 mm/min, the heating temperature Ti = 250 °C.
{"title":"Research of KFRP tool heating drilling based on the cutting-edge force-heat concentration effect and novel tool structure design","authors":"Fei Su, Xinzhe Zhang, Yan Che","doi":"10.1016/j.jmapro.2024.12.040","DOIUrl":"10.1016/j.jmapro.2024.12.040","url":null,"abstract":"<div><div>Kevlar fiber reinforced plastic (KFRP) is widely used in military industry and aircraft field. Traditional mechanical drilling often leads to defects such as delamination and fiber drawing. The processing technology significantly influences the defects in hole drilling. In this paper, given the high thermal sensitivity of KFRP, a rotary cutting process with induction heating of the tool is proposed, and a corresponding tool structure is designed. Upon application of heat to the tool, the highest temperature of the tool tip is transferred instantaneously to the workpiece material in the cutting area. As the temperature of the material rises, its mechanical properties decline. There is a significant force-heat concentration effect in the advance of the tool. The application of force and heat results in a reduction of thermal damage in the cutting zone, accompanied by a notable decrease in the formation of fiber drawing and delamination. The best surface quality of the hole is achieved when the feed speed <em>V</em><sub>f</sub> = 210 mm/min, the heating temperature <em>T</em><sub>i</sub> = 250 °C.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 505-529"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132660","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 : 2025-01-31DOI: 10.1016/j.jmapro.2024.12.021
Hongyan Zhou, Fuji Wang, Shiwei Zhang, Yongquan Lin, Gang Wei
At the hole exit when drilling thermoplastic composites, the weakly constrained fibers tend to deform, making them difficult to remove under the cutting of the main cutting-edge and the margin-edge. Additionally, tough matrix deforms without breaking, leading to a complex material removal process and damage behavior at hole exit. This study establishes a microscopic model that describes the removal state of brittle fibers and a ductile matrix under weak constraints. It reveals the material removal process and damage mechanism at hole exit in drilling CF/PEEK composites during sequential cutting by the main cutting-edge and margin-edge at low feed rates (f < 0.1 mm/r). Both simulation and experimental results indicate that, due to the high toughness of the matrix, the out-of-plane deformation caused by the main cutting-edge and the initial cracks have almost no direct correlation with the damage at the hole exit. Instead, the subsurface bending fracture of fibers and the mode III crack propagation induced by the margin-edge cutting directly lead to the formation of final damage. The prediction error of damage depth is <8 %. Based on the model, the study analyzes furtherly the potential mechanism by which damage at hole exit in drilling thermoplastic composites decreases with increasing feed rates.
{"title":"Analysis of material removal behavior and damage mechanism at hole exit in drilling high-toughness CF/PEEK composites","authors":"Hongyan Zhou, Fuji Wang, Shiwei Zhang, Yongquan Lin, Gang Wei","doi":"10.1016/j.jmapro.2024.12.021","DOIUrl":"10.1016/j.jmapro.2024.12.021","url":null,"abstract":"<div><div>At the hole exit when drilling thermoplastic composites, the weakly constrained fibers tend to deform, making them difficult to remove under the cutting of the main cutting-edge and the margin-edge. Additionally, tough matrix deforms without breaking, leading to a complex material removal process and damage behavior at hole exit. This study establishes a microscopic model that describes the removal state of brittle fibers and a ductile matrix under weak constraints. It reveals the material removal process and damage mechanism at hole exit in drilling CF/PEEK composites during sequential cutting by the main cutting-edge and margin-edge at low feed rates (f < 0.1 mm/r). Both simulation and experimental results indicate that, due to the high toughness of the matrix, the out-of-plane deformation caused by the main cutting-edge and the initial cracks have almost no direct correlation with the damage at the hole exit. Instead, the subsurface bending fracture of fibers and the mode III crack propagation induced by the margin-edge cutting directly lead to the formation of final damage. The prediction error of damage depth is <8 %. Based on the model, the study analyzes furtherly the potential mechanism by which damage at hole exit in drilling thermoplastic composites decreases with increasing feed rates.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 107-116"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132272","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 : 2025-01-31DOI: 10.1016/j.jmapro.2024.12.079
Yuanhao Fan , Junxue Ren , Kaining Shi , Yiran Tang , Xiangyu Li , Congle Liu
Increasingly, new structures are being incorporated into the design of engine components to satisfy the aircraft pursuit of the high thrust-to-weight ratio. As machining requirements surpass the capabilities of traditional structured tools, there is the growing trend towards the design and application of tools with complex features, such as tapered or arcuate structures. In actual machining, issues such as decreased machining accuracy and deteriorated surface quality caused by the deformation of such tools still exist widely. Traditional computational methods fall short in providing accurate calculations for the deformation of such specialized tools, due to the complexity of their structure. Based on the generic multi-parameter model of the tool structure and the subcomponent method, this paper proposes the calculation method for bending deformation of milling tools, tailored to complex structured tools. The Generic Multi-Parameter Tool Model (GMPTM) that represents the overall structure of the tool is developed using the Automatically Programmed Tools model as the foundation. Guided by geometric features, the tool is subdivided into subcomponents according to the GMPTM. By combining the approximate differential equation of the cantilever beam deflection curve with the boundary constraints between subcomponents, the overall bending deformation equation of the tool is obtained by assembling the deformation equations of the subcomponents. The derivation processes for the bending deformation equations are provided respectively for the tool arbor subcomponents (cylindrical, tapered and arcuate) and the tool body subcomponent. To ensure the accuracy of deformation calculation, an equivalent diameter calibration method for the tool body subcomponent based on experimental deformation data is proposed. The analysis of experimental results for seven different tool shapes, combined with the comparison to existing computational methods, confirms the reliability and applicability of the bending deformation calculation method for complex-structured tools, offering the effective solution to address deformation challenges in such tools.
{"title":"Calculation method for bending deformation of complex structured tools based on subcomponent method","authors":"Yuanhao Fan , Junxue Ren , Kaining Shi , Yiran Tang , Xiangyu Li , Congle Liu","doi":"10.1016/j.jmapro.2024.12.079","DOIUrl":"10.1016/j.jmapro.2024.12.079","url":null,"abstract":"<div><div>Increasingly, new structures are being incorporated into the design of engine components to satisfy the aircraft pursuit of the high thrust-to-weight ratio. As machining requirements surpass the capabilities of traditional structured tools, there is the growing trend towards the design and application of tools with complex features, such as tapered or arcuate structures. In actual machining, issues such as decreased machining accuracy and deteriorated surface quality caused by the deformation of such tools still exist widely. Traditional computational methods fall short in providing accurate calculations for the deformation of such specialized tools, due to the complexity of their structure. Based on the generic multi-parameter model of the tool structure and the subcomponent method, this paper proposes the calculation method for bending deformation of milling tools, tailored to complex structured tools. The Generic Multi-Parameter Tool Model (GMPTM) that represents the overall structure of the tool is developed using the Automatically Programmed Tools model as the foundation. Guided by geometric features, the tool is subdivided into subcomponents according to the GMPTM. By combining the approximate differential equation of the cantilever beam deflection curve with the boundary constraints between subcomponents, the overall bending deformation equation of the tool is obtained by assembling the deformation equations of the subcomponents. The derivation processes for the bending deformation equations are provided respectively for the tool arbor subcomponents (cylindrical, tapered and arcuate) and the tool body subcomponent. To ensure the accuracy of deformation calculation, an equivalent diameter calibration method for the tool body subcomponent based on experimental deformation data is proposed. The analysis of experimental results for seven different tool shapes, combined with the comparison to existing computational methods, confirms the reliability and applicability of the bending deformation calculation method for complex-structured tools, offering the effective solution to address deformation challenges in such tools.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 790-813"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131741","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 : 2025-01-31DOI: 10.1016/j.jmapro.2025.01.018
Yanfeng Zhang , Yuchen Min , Feng Ding , Yong Li , Yao Wang , Jianning Du , Xiuyu Jiang , Lin Wang
Fiber Metal Laminates (FMLs) are considered ultra-hybrid composites due to their exceptional fatigue resistance and high damage tolerance. These characteristics make them ideal for critical thin-walled components in large aircraft. However, the forming and manufacturing of heterogeneous components is challenging due to the significant differences in their properties, the complexity of interfaces, and various defects like delamination and fracture. Focusing on the interface/interlaminar deformation-impregnation issue, this study proposed an in-situ dynamic impregnation forming method to transform the traditional static resin injection composite molding into a synchronized dynamic injection coupled with deep drawing. A specialized experimental setup was established to investigate the influence of injection flow rate on in-situ forming, the correlation of the injection starting point and the deep drawing depth, and the coupling mechanism between deep drawing speed and injection flow rate. The results revealed that an excessively high injection flow rate causes a bulging effect, causing laminate failure due to expansion and rupturing. Simultaneously, the injection flow rate critically affects the formation and location of pores. The injection starting point affects the resin flow direction and distribution between layers, and some defects may occur, such as resin overflow, wrinkling, misalignment, and dry spots. When the injection starting point is set at 0 % of the punch stroke, the resin injection begins at the start of deep drawing, improving the forming process quality. However, a mismatch between the deep drawing speed and the injection speed can affect the friction state and fiber deformation at the small intricate features, leading to defects such as pores, wrinkling, delamination, and interface debonding, which affect the interfacial bonding effect. This study provides a theoretical foundation for the in-depth analysis of the in-situ dynamic impregnation forming of Al/GFRP laminates, thereby promoting the applications of laminates.
{"title":"Investigation on in-situ dynamic impregnation forming mechanism of fiber metal superhybrid laminates","authors":"Yanfeng Zhang , Yuchen Min , Feng Ding , Yong Li , Yao Wang , Jianning Du , Xiuyu Jiang , Lin Wang","doi":"10.1016/j.jmapro.2025.01.018","DOIUrl":"10.1016/j.jmapro.2025.01.018","url":null,"abstract":"<div><div>Fiber Metal Laminates (FMLs) are considered ultra-hybrid composites due to their exceptional fatigue resistance and high damage tolerance. These characteristics make them ideal for critical thin-walled components in large aircraft. However, the forming and manufacturing of heterogeneous components is challenging due to the significant differences in their properties, the complexity of interfaces, and various defects like delamination and fracture. Focusing on the interface/interlaminar deformation-impregnation issue, this study proposed an in-situ dynamic impregnation forming method to transform the traditional static resin injection composite molding into a synchronized dynamic injection coupled with deep drawing. A specialized experimental setup was established to investigate the influence of injection flow rate on in-situ forming, the correlation of the injection starting point and the deep drawing depth, and the coupling mechanism between deep drawing speed and injection flow rate. The results revealed that an excessively high injection flow rate causes a bulging effect, causing laminate failure due to expansion and rupturing. Simultaneously, the injection flow rate critically affects the formation and location of pores. The injection starting point affects the resin flow direction and distribution between layers, and some defects may occur, such as resin overflow, wrinkling, misalignment, and dry spots. When the injection starting point is set at 0 % of the punch stroke, the resin injection begins at the start of deep drawing, improving the forming process quality. However, a mismatch between the deep drawing speed and the injection speed can affect the friction state and fiber deformation at the small intricate features, leading to defects such as pores, wrinkling, delamination, and interface debonding, which affect the interfacial bonding effect. This study provides a theoretical foundation for the in-depth analysis of the in-situ dynamic impregnation forming of Al/GFRP laminates, thereby promoting the applications of laminates.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 866-879"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131744","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 : 2025-01-31DOI: 10.1016/j.jmapro.2024.12.075
Pengyang Li , Jian Sun , Jian Li , Ruiyuan Zhang , Guoqing Chen
Carbon fiber reinforced polymer (CFRP) composites have been extensively utilized in the aerospace industry due to their exceptional mechanical and physical properties. However, the drilling process of carbon fiber composites is challenging due to their structural anisotropy, abrasiveness, and low thermal conductivity. To enhance processing quality, rotary ultrasonic longitudinal torsional vibration drilling (RULTVD) technology is employed for CFRP composite processing. Based on kinematics principles, a kinematics model of a single cutting edge is established, and the influence of separation characteristics on RULTVD machining is discussed. The effects of spindle speed, feed rate, and longitudinal-torsional amplitude on cutting force and hole export defects are investigated through experimental methods. The experimental results demonstrate that ultrasonic longitudinal-torsional drilling reduces the cutting force by 17.8 % compared to conventional drilling while decreasing the maximum delamination factor by 8.6 %. These findings validate that rotary ultrasonic longitudinal-torsional drilling significantly alleviates the processing challenges associated with carbon fiber reinforced composites while improving processing quality.
{"title":"Study on drilling force and export defects of CFRP composites in RULTVD","authors":"Pengyang Li , Jian Sun , Jian Li , Ruiyuan Zhang , Guoqing Chen","doi":"10.1016/j.jmapro.2024.12.075","DOIUrl":"10.1016/j.jmapro.2024.12.075","url":null,"abstract":"<div><div>Carbon fiber reinforced polymer (CFRP) composites have been extensively utilized in the aerospace industry due to their exceptional mechanical and physical properties. However, the drilling process of carbon fiber composites is challenging due to their structural anisotropy, abrasiveness, and low thermal conductivity. To enhance processing quality, rotary ultrasonic longitudinal torsional vibration drilling (RULTVD) technology is employed for CFRP composite processing. Based on kinematics principles, a kinematics model of a single cutting edge is established, and the influence of separation characteristics on RULTVD machining is discussed. The effects of spindle speed, feed rate, and longitudinal-torsional amplitude on cutting force and hole export defects are investigated through experimental methods. The experimental results demonstrate that ultrasonic longitudinal-torsional drilling reduces the cutting force by 17.8 % compared to conventional drilling while decreasing the maximum delamination factor by 8.6 %. These findings validate that rotary ultrasonic longitudinal-torsional drilling significantly alleviates the processing challenges associated with carbon fiber reinforced composites while improving processing quality.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 880-890"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131773","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 : 2025-01-31DOI: 10.1016/j.jmapro.2025.01.007
Zhiqing Zhang , Yanye Jin , Lin Ma , Shude Ji , Jihong Dong , Huaxia Zhao , Zelin Sun , Qi Song
Plunging the pin of rotating tool into lower sheet is a common process in the aluminum alloys friction stir lap welding (FSLW) field for obtaining the discontinuously-distributed lap interface in weld nugget zone (NZ), but unavoidable up-bending morphology of hook outside NZ greatly reduces the bearing capacity of lap joint. In this study, the novel impacting flow FSLW (IF-FSLW) process was employed by the rotating tool with an X-shape reverse-threaded pin. 2024 aluminum alloys were selected as base material (BM), and three rotating tools with different junction points on the pin were developed to analyze how material concentrated zone (MCZ) influenced the formation and bearing capacity of lap joint. Results showed that the hook with the forky structure was formed under the horizontally-pushing effect of MCZ on the original lap interface, and the hook with the down-bending morphology was induced by the vertically-squeezing effect of MCZ above the original lap interface. The tensile fracture mode of IF-FSLW joint was obtained under the combined actions of the down-bending hook, the largely shortened cold lap and the substantially enlarged NZ, and the corresponding welded lap joint had an incredible tensile strength. The IF-FSLW joint with the maximum tensile strength of 410 MPa was obtained, and the joint efficiency reached 92 % with respect to the BM. The IF-FSLW technology assisted with the X-shape reverse-threaded pin puts forward an effective approach to make a lap joint with superb strength.
{"title":"A general strategy for achieving high-strength joining of 2024 aluminum alloys via impacting flow friction stir lap welding","authors":"Zhiqing Zhang , Yanye Jin , Lin Ma , Shude Ji , Jihong Dong , Huaxia Zhao , Zelin Sun , Qi Song","doi":"10.1016/j.jmapro.2025.01.007","DOIUrl":"10.1016/j.jmapro.2025.01.007","url":null,"abstract":"<div><div>Plunging the pin of rotating tool into lower sheet is a common process in the aluminum alloys friction stir lap welding (FSLW) field for obtaining the discontinuously-distributed lap interface in weld nugget zone (NZ), but unavoidable up-bending morphology of hook outside NZ greatly reduces the bearing capacity of lap joint. In this study, the novel impacting flow FSLW (IF-FSLW) process was employed by the rotating tool with an X-shape reverse-threaded pin. 2024 aluminum alloys were selected as base material (BM), and three rotating tools with different junction points on the pin were developed to analyze how material concentrated zone (MCZ) influenced the formation and bearing capacity of lap joint. Results showed that the hook with the forky structure was formed under the horizontally-pushing effect of MCZ on the original lap interface, and the hook with the down-bending morphology was induced by the vertically-squeezing effect of MCZ above the original lap interface. The tensile fracture mode of IF-FSLW joint was obtained under the combined actions of the down-bending hook, the largely shortened cold lap and the substantially enlarged NZ, and the corresponding welded lap joint had an incredible tensile strength. The IF-FSLW joint with the maximum tensile strength of 410 MPa was obtained, and the joint efficiency reached 92 % with respect to the BM. The IF-FSLW technology assisted with the X-shape reverse-threaded pin puts forward an effective approach to make a lap joint with superb strength.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 619-632"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131930","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}
Cryogenic abrasive air-jet machining (CAJM) technology is widely used to create microchannels in polydimethylsiloxane (PDMS) material, where the cooling temperature distribution directly affects the abrasive embedding degree and surface quality of the eroded surface. At present, the researchers assumed that the convective heat transfer coefficient of PDMS material remains unchanged during the heat transfer process of LN2 jet impact, and carried out the finite element analysis of the cooling temperature distribution of PDMS. However, the definition of effective embrittlement domain of PDMS material, that avoids the abrasive embedding, is still an unsolved problem. In this work, Beck's method and thermocouple temperature data are used to obtain the convective heat transfer coefficient during LN2 jet cooling of the PDMS substrate. Based on the analysis of the PDMS material cooling temperature field, the evolution law of abrasive embedding degree in different embrittlement domains are predicted and analyzed. The research results show that the proposed systematic research method of LN2 jet cooling temperature distribution of the PDMS material, based on Beck's method, has obtained the critical process conditions for effective embrittlement domain definition in PDMS material erosion processing by adjusting the LN2 jet nozzle traverse speed for the first time. This study provides a theoretical basis for the non-abrasive embedded eroded surface of PDMS materials in the range of large impact angles.
{"title":"Clarification of the effect of cooling rate on abrasive embedding behavior of PDMS in cryogenic abrasive air-jet machining","authors":"Guiguan Zhang , Wentian Ma , Yuewu Gao , Yugang Zhao , Guoyong Zhao , Jianbing Meng , Dunwen Zuo , Yuli Sun","doi":"10.1016/j.jmapro.2025.01.016","DOIUrl":"10.1016/j.jmapro.2025.01.016","url":null,"abstract":"<div><div>Cryogenic abrasive air-jet machining (CAJM) technology is widely used to create microchannels in polydimethylsiloxane (PDMS) material, where the cooling temperature distribution directly affects the abrasive embedding degree and surface quality of the eroded surface. At present, the researchers assumed that the convective heat transfer coefficient of PDMS material remains unchanged during the heat transfer process of LN<sub>2</sub> jet impact, and carried out the finite element analysis of the cooling temperature distribution of PDMS. However, the definition of effective embrittlement domain of PDMS material, that avoids the abrasive embedding, is still an unsolved problem. In this work, Beck's method and thermocouple temperature data are used to obtain the convective heat transfer coefficient during LN<sub>2</sub> jet cooling of the PDMS substrate. Based on the analysis of the PDMS material cooling temperature field, the evolution law of abrasive embedding degree in different embrittlement domains are predicted and analyzed. The research results show that the proposed systematic research method of LN<sub>2</sub> jet cooling temperature distribution of the PDMS material, based on Beck's method, has obtained the critical process conditions for effective embrittlement domain definition in PDMS material erosion processing by adjusting the LN<sub>2</sub> jet nozzle traverse speed for the first time. This study provides a theoretical basis for the non-abrasive embedded eroded surface of PDMS materials in the range of large impact angles.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 749-761"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131946","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 : 2025-01-31DOI: 10.1016/j.jmapro.2025.01.024
M. Etxebeste, G. Ortiz-de-Zarate, I.M. Arrieta, P.J. Arrazola
Large cutting tools are widely used in sectors such as automotive, where complex shape aluminium components are machined at high cutting speeds, in a single clamping and in short cycle times with elevated Material Removal Rate (MRR). However, their relatively low stiffness and natural frequencies make chatter the primary productivity limitation. Developing optimised tools to overcome these limitations is often cost-prohibitive with current design methods. This paper presents a virtual design methodology for optimising large milling tools to mitigate chatter through topology optimisation and Finite Element Modal Analysis (FEMA). Topology optimisation enhanced tool dynamics, enabling chatter reduction under higher productivity conditions. An improved FEMA model was developed to accurately predict the modal parameters of the cutting tools, featuring a high-fidelity representation of the tool-holder clamping to the spindle. The predicted modal parameters enable cost-effective chatter prediction for tool design validations, minimising development and experimental costs. To validate the methodology, a prototype of the optimised tool was manufactured and tested through experimental modal analysis and machining tests, demonstrating significant productivity improvement in MRR compared to the initial design.
{"title":"A virtual design methodology to improve the dynamics and productivity of large milling tools","authors":"M. Etxebeste, G. Ortiz-de-Zarate, I.M. Arrieta, P.J. Arrazola","doi":"10.1016/j.jmapro.2025.01.024","DOIUrl":"10.1016/j.jmapro.2025.01.024","url":null,"abstract":"<div><div>Large cutting tools are widely used in sectors such as automotive, where complex shape aluminium components are machined at high cutting speeds, in a single clamping and in short cycle times with elevated Material Removal Rate (MRR). However, their relatively low stiffness and natural frequencies make chatter the primary productivity limitation. Developing optimised tools to overcome these limitations is often cost-prohibitive with current design methods. This paper presents a virtual design methodology for optimising large milling tools to mitigate chatter through topology optimisation and Finite Element Modal Analysis (FEMA). Topology optimisation enhanced tool dynamics, enabling chatter reduction under higher productivity conditions. An improved FEMA model was developed to accurately predict the modal parameters of the cutting tools, featuring a high-fidelity representation of the tool-holder clamping to the spindle. The predicted modal parameters enable cost-effective chatter prediction for tool design validations, minimising development and experimental costs. To validate the methodology, a prototype of the optimised tool was manufactured and tested through experimental modal analysis and machining tests, demonstrating significant productivity improvement in MRR compared to the initial design.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 1096-1113"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132041","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 : 2025-01-31DOI: 10.1016/j.jmapro.2024.12.050
Zhichao Geng, Yang He, Fengzhou Fang
Reaction-sintered silicon carbide (RS-SiC) is widely used in optical mirrors for space exploration. Maintaining surface integrity by obtaining both high surface finish and minimal subsurface damage is critical for achieving optimal performance. However, conventional machining processes struggle to meet these requirements because of high hardness and brittleness of RS-SiC. This paper presents a novel photocatalysis/vibration-assisted finishing technique and provides a systematic analysis of polished RS-SiC, including surface and subsurface characteristics. The involved process generates a softer, smoother, and amorphous oxide layer, significantly enhancing polishing efficiency and achieving a surface roughness of 0.25 nm in Ra. And the subsurface damage is minimized effectively. This study confirms that photocatalysis/vibration-assisted finishing is an eco-friendly ultra-precision polishing technology with the potential to achieve damage-free processing.
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