Pub Date : 2026-01-22DOI: 10.1016/j.jmapro.2026.01.030
Yan Zhou , Dan Chen , Pengfei Wang , Zhaoxiao Wu , Leqiang Deng , Xue Xiao , Jiuxiang Qin , Chengxiang Li
This study aims to addresses the challenge of electromagnetic pulse welding (EMPW) laminated workpieces (tabs and busbar of lithium-ion batteries (LIBs)) for electric vehicles (EVs), where the tabs and busbar are normally stacked closely together without enough standoff distance that required for EMPW. We propose a novel EMPW method for laminated workpieces based on a gradient through-hole (GTH) structure without standoff distance. When the discharge energy was 15.75 kJ, a 1 mm-thick Al sheet (driver sheet), four layers 0.3 mm-thick Al sheets (tabs), and a 1 mm-thick Cu sheet (busbar) were successfully welded. The mechanical properties and contact resistance of the EMPW welded joint were tested. The influence of discharge energy on the mechanical properties of the joint was also investigated. Scanning Electron Microscope (SEM), Energy Dispersive Spectrometer (EDS), Electron Backscattered Diffraction (EBSD), and Transmission Electron Microscopy (TEM) were used to characterize and analyze the bonding interface microstructure. The results show that a wavy interface is found between the driver sheet and the busbar. The AlCu intermetallic compounds are found, and grain refinement and element interdiffusion occur at the interface. There is no obvious boundary between each layer of tab. Compared with the straight through-hole (STH) structure, the EMPW welded joint obtained by the GTH structure achieves a larger contact surface area, better mechanical properties, and better electrical properties. This study provides a new EMPW method for welding laminated workpieces of the LIBs.
{"title":"Electromagnetic pulse welding of lithium-ion battery laminated workpieces based on a gradient through-hole structure","authors":"Yan Zhou , Dan Chen , Pengfei Wang , Zhaoxiao Wu , Leqiang Deng , Xue Xiao , Jiuxiang Qin , Chengxiang Li","doi":"10.1016/j.jmapro.2026.01.030","DOIUrl":"10.1016/j.jmapro.2026.01.030","url":null,"abstract":"<div><div>This study aims to addresses the challenge of electromagnetic pulse welding (EMPW) laminated workpieces (tabs and busbar of lithium-ion batteries (LIBs)) for electric vehicles (EVs), where the tabs and busbar are normally stacked closely together without enough standoff distance that required for EMPW. We propose a novel EMPW method for laminated workpieces based on a gradient through-hole (GTH) structure without standoff distance. When the discharge energy was 15.75 kJ, a 1 mm-thick Al sheet (driver sheet), four layers 0.3 mm-thick Al sheets (tabs), and a 1 mm-thick Cu sheet (busbar) were successfully welded. The mechanical properties and contact resistance of the EMPW welded joint were tested. The influence of discharge energy on the mechanical properties of the joint was also investigated. Scanning Electron Microscope (SEM), Energy Dispersive Spectrometer (EDS), Electron Backscattered Diffraction (EBSD), and Transmission Electron Microscopy (TEM) were used to characterize and analyze the bonding interface microstructure. The results show that a wavy interface is found between the driver sheet and the busbar. The AlCu intermetallic compounds are found, and grain refinement and element interdiffusion occur at the interface. There is no obvious boundary between each layer of tab. Compared with the straight through-hole (STH) structure, the EMPW welded joint obtained by the GTH structure achieves a larger contact surface area, better mechanical properties, and better electrical properties. This study provides a new EMPW method for welding laminated workpieces of the LIBs.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 254-269"},"PeriodicalIF":6.8,"publicationDate":"2026-01-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036899","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 : 2026-01-22DOI: 10.1016/j.jmapro.2026.01.021
Desheng Hu , Caixu Yue , Zhipeng Jiang , Xianli Liu , Zhonghua Li , Steven Y. Liang
Characterized by high efficiency and versatility in various cutting processes, the indexable insert drill is extensively used in aerospace and energy equipment. Nevertheless, the deep hole drilling process generates significant heat and strain, posing a challenge to the blade's service life. Therefore, to accurately simulate the machining characteristics of indexable insert drilling, an improved simulation method for blind hole drilling of indexable inserts considering coolant-assisted machining is proposed. Firstly, the Coupled Euler-Lagrange (CEL) method is used to characterize the fluid field of the coolant and the solid field of the tool-workpiece, and the multi-field coupling drilling simulation model is established by combining the thermal-force field. Then, according to the wear mechanism of the blade, the variable condition drilling experiment is carried out. The Usui wear rate model was constructed by measuring the wear rate, cutting temperature, and tool-workpiece contact stress at different cutting speeds (140 m/min, 160 m/min, 180 m/min, and 200 m/min). Further, the model is integrated into the simulation software through secondary development. According to the simulation results, the prediction error of the blade wear rate is 12.65%. Finally, the validation experiment involving 42CrMo drilling confirms the superior predictive performance of the improved model, which incorporates coolant effects, compared to traditional simulation methodologies. The torque prediction error is reduced from 22.75% to 12.80%, and the workpiece temperature prediction error is reduced from 16.78% to 12.63%. This work can provide a basis for a deeper understanding of the blade failure mechanism and suggest directions for optimizing tool structure and process parameters.
{"title":"Simulation research on drilling characteristics of indexable insert drilling blind hole based on multi-field coupling strategy","authors":"Desheng Hu , Caixu Yue , Zhipeng Jiang , Xianli Liu , Zhonghua Li , Steven Y. Liang","doi":"10.1016/j.jmapro.2026.01.021","DOIUrl":"10.1016/j.jmapro.2026.01.021","url":null,"abstract":"<div><div>Characterized by high efficiency and versatility in various cutting processes, the indexable insert drill is extensively used in aerospace and energy equipment. Nevertheless, the deep hole drilling process generates significant heat and strain, posing a challenge to the blade's service life. Therefore, to accurately simulate the machining characteristics of indexable insert drilling, an improved simulation method for blind hole drilling of indexable inserts considering coolant-assisted machining is proposed. Firstly, the Coupled Euler-Lagrange (CEL) method is used to characterize the fluid field of the coolant and the solid field of the tool-workpiece, and the multi-field coupling drilling simulation model is established by combining the thermal-force field. Then, according to the wear mechanism of the blade, the variable condition drilling experiment is carried out. The Usui wear rate model was constructed by measuring the wear rate, cutting temperature, and tool-workpiece contact stress at different cutting speeds (140 m/min, 160 m/min, 180 m/min, and 200 m/min). Further, the model is integrated into the simulation software through secondary development. According to the simulation results, the prediction error of the blade wear rate is 12.65%. Finally, the validation experiment involving 42CrMo drilling confirms the superior predictive performance of the improved model, which incorporates coolant effects, compared to traditional simulation methodologies. The torque prediction error is reduced from 22.75% to 12.80%, and the workpiece temperature prediction error is reduced from 16.78% to 12.63%. This work can provide a basis for a deeper understanding of the blade failure mechanism and suggest directions for optimizing tool structure and process parameters.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 481-496"},"PeriodicalIF":6.8,"publicationDate":"2026-01-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024738","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}
This paper presents a hybrid process- electric arc electrochemical machining (EAECM). This process utilizes synergistic effect of discharge and dissolution to achieve efficient and high quality manufacturing. The surface polishing characteristics, formation and dissolution behavior of recast layer, overcutting, electrode wear mechanism, and product properties of EAECM were experimentally investigated. The results show that EAECM can dissolve recast layer and polish surface at non-discharge moments while maintaining the efficiency of EAM. There is significant anisotropy in the recast layer, and the solidification rate difference also leads to the proliferation of internal grain dislocations, causing residual tensile stress to fail the material. EAECM eliminates the residual tensile stress during machining and restores the material's own property. In addition, EAECM has a heat diffusion inhibition behavior, which has a protective effect on the substrate. The alternating discharge and dissolution points of EAECM, combined with the limited dissolution time of the high-speed moving electrode, the electrolyte concentration of 10–15 Wt% is still no over-corrosion. The synergistic effect of lightweight electrolytic products with tiny volume and safe distance improves the discharge state and reduces the electrode wear, consequently maintaining the shape accuracy. The process performance of conventional electric arc machining (EAM) and EAECM was compared to demonstrate the process value of EAECM. Parameter optimization was also performed to enhance the process potential. Finally, the engineering potential of EAECM was demonstrated by some artifacts.
{"title":"Electric arc electrochemical machining: Synergistic effect, material removal mechanism and process research","authors":"Shengsheng Zhang , Yinan Zhao , Jianping Zhou , Xiaoxiao Chen , Yufeng Wang , Wenwu Zhang","doi":"10.1016/j.jmapro.2026.01.057","DOIUrl":"10.1016/j.jmapro.2026.01.057","url":null,"abstract":"<div><div>This paper presents a hybrid process- electric arc electrochemical machining (EAECM). This process utilizes synergistic effect of discharge and dissolution to achieve efficient and high quality manufacturing. The surface polishing characteristics, formation and dissolution behavior of recast layer, overcutting, electrode wear mechanism, and product properties of EAECM were experimentally investigated. The results show that EAECM can dissolve recast layer and polish surface at non-discharge moments while maintaining the efficiency of EAM. There is significant anisotropy in the recast layer, and the solidification rate difference also leads to the proliferation of internal grain dislocations, causing residual tensile stress to fail the material. EAECM eliminates the residual tensile stress during machining and restores the material's own property. In addition, EAECM has a heat diffusion inhibition behavior, which has a protective effect on the substrate. The alternating discharge and dissolution points of EAECM, combined with the limited dissolution time of the high-speed moving electrode, the electrolyte concentration of 10–15 Wt% is still no over-corrosion. The synergistic effect of lightweight electrolytic products with tiny volume and safe distance improves the discharge state and reduces the electrode wear, consequently maintaining the shape accuracy. The process performance of conventional electric arc machining (EAM) and EAECM was compared to demonstrate the process value of EAECM. Parameter optimization was also performed to enhance the process potential. Finally, the engineering potential of EAECM was demonstrated by some artifacts.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 222-241"},"PeriodicalIF":6.8,"publicationDate":"2026-01-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036897","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 : 2026-01-22DOI: 10.1016/j.jmapro.2026.01.045
Xiaoyu Zhao , Lai Zou , Kangkang Song , Wenxi Wang , Yilin Mu
Compliant robotic belt grinding is widely used for finishing complex components like turbine blades and blisks. However, conventional geometric models often fail to predict residual height accurately under force-compliant conditions. This inaccuracy arises because the actual material removal profile is dynamically distorted by the coupling of contact wheel elastic deformation and time-varying abrasive wear. To address these effects, an improved residual height model is presented for structured abrasive belts. By integrating Hertzian contact mechanics and Archard's wear law, the model explicitly quantifies the over-grinding effect caused by pressure superposition in overlapping zones and the degradation of abrasive grains. Based on this predictive model, a dwell-time optimization strategy is formulated to coordinate process efficiency and contour precision under constraints of residual height, chord error, and allowance matching. Experimental validation on curved TC4 titanium alloy components shows that the proposed approach reduces residual height prediction error to within ±10 μm. Under the tested conditions, surface roughness decreased by approximately 30%, and profile accuracy by 25% compared to constant-feed strategies, demonstrating the engineering feasibility of the proposed framework.
{"title":"An improved residual height model for compliant robotic belt grinding with application to dwell time optimization","authors":"Xiaoyu Zhao , Lai Zou , Kangkang Song , Wenxi Wang , Yilin Mu","doi":"10.1016/j.jmapro.2026.01.045","DOIUrl":"10.1016/j.jmapro.2026.01.045","url":null,"abstract":"<div><div>Compliant robotic belt grinding is widely used for finishing complex components like turbine blades and blisks. However, conventional geometric models often fail to predict residual height accurately under force-compliant conditions. This inaccuracy arises because the actual material removal profile is dynamically distorted by the coupling of contact wheel elastic deformation and time-varying abrasive wear. To address these effects, an improved residual height model is presented for structured abrasive belts. By integrating Hertzian contact mechanics and Archard's wear law, the model explicitly quantifies the over-grinding effect caused by pressure superposition in overlapping zones and the degradation of abrasive grains. Based on this predictive model, a dwell-time optimization strategy is formulated to coordinate process efficiency and contour precision under constraints of residual height, chord error, and allowance matching. Experimental validation on curved TC4 titanium alloy components shows that the proposed approach reduces residual height prediction error to within ±10 μm. Under the tested conditions, surface roughness decreased by approximately 30%, and profile accuracy by 25% compared to constant-feed strategies, demonstrating the engineering feasibility of the proposed framework.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 200-221"},"PeriodicalIF":6.8,"publicationDate":"2026-01-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036896","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 : 2026-01-21DOI: 10.1016/j.jmapro.2026.01.073
Claudio Esposito, Marco Trofa, Daniele Tammaro, Lorenzo Lombardi, Gaetano D’Avino, Pier Luca Maffettone
Foam extrusion through slit dies often suffers from shape asymmetry that compromise product quality and increase waste. This work combines experiments and computational fluid dynamics simulations to investigate the influence of die geometry and pulling velocity on foam board morphology. Two slit dies with different central heights are tested at varying pulling speeds using low-density polyethylene with isobutane as a blowing agent. Experiments show that dies with a large central height promote nearly rectangular boards with uniform bubble morphology, whereas those with a small gap produce pronounced N-shaped distortions and surface irregularities. Higher pulling velocity mitigates asymmetry of the extrudate shape but reduces expansion and leads to smaller, more elongated bubbles due to rapid quenching. Despite employing a simplified Newtonian rheology and a reduced computational domain, simulations qualitatively reproduce the experimental trends, elucidating the contribution of the velocity and pressure gradients at the die exit that drive asymmetric expansion.
{"title":"Experimental and numerical investigation of shape asymmetry in slit die foam extrusion","authors":"Claudio Esposito, Marco Trofa, Daniele Tammaro, Lorenzo Lombardi, Gaetano D’Avino, Pier Luca Maffettone","doi":"10.1016/j.jmapro.2026.01.073","DOIUrl":"10.1016/j.jmapro.2026.01.073","url":null,"abstract":"<div><div>Foam extrusion through slit dies often suffers from shape asymmetry that compromise product quality and increase waste. This work combines experiments and computational fluid dynamics simulations to investigate the influence of die geometry and pulling velocity on foam board morphology. Two slit dies with different central heights are tested at varying pulling speeds using low-density polyethylene with isobutane as a blowing agent. Experiments show that dies with a large central height promote nearly rectangular boards with uniform bubble morphology, whereas those with a small gap produce pronounced N-shaped distortions and surface irregularities. Higher pulling velocity mitigates asymmetry of the extrudate shape but reduces expansion and leads to smaller, more elongated bubbles due to rapid quenching. Despite employing a simplified Newtonian rheology and a reduced computational domain, simulations qualitatively reproduce the experimental trends, elucidating the contribution of the velocity and pressure gradients at the die exit that drive asymmetric expansion.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 99-110"},"PeriodicalIF":6.8,"publicationDate":"2026-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036891","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 : 2026-01-21DOI: 10.1016/j.jmapro.2026.01.037
Luke Rimac, Philip Koshy, Mohamed Elbestawi
This research investigated snaking chatter in grooving blades that causes an inconsistent increase in groove width relative to the tool width, often exceeding tolerance limits in precision applications. Contrary to the suggestion in the literature attributing snaking chatter to mode coupling, this study proposed and verified the hypothesis that it arises instead from regenerative effects on the side walls of the machined groove. With the application of a conventional stability-based process design shown infeasible in addressing snaking chatter, a counterintuitive mitigation strategy that concomitantly delivers a 450% increase in the material removal rate over the state of the art is demonstrated.
{"title":"Snaking chatter: Mechanism and mitigation","authors":"Luke Rimac, Philip Koshy, Mohamed Elbestawi","doi":"10.1016/j.jmapro.2026.01.037","DOIUrl":"10.1016/j.jmapro.2026.01.037","url":null,"abstract":"<div><div>This research investigated snaking chatter in grooving blades that causes an inconsistent increase in groove width relative to the tool width, often exceeding tolerance limits in precision applications. Contrary to the suggestion in the literature attributing snaking chatter to mode coupling, this study proposed and verified the hypothesis that it arises instead from regenerative effects on the side walls of the machined groove. With the application of a conventional stability-based process design shown infeasible in addressing snaking chatter, a counterintuitive mitigation strategy that concomitantly delivers a 450% increase in the material removal rate over the state of the art is demonstrated.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 134-141"},"PeriodicalIF":6.8,"publicationDate":"2026-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036894","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 : 2026-01-21DOI: 10.1016/j.jmapro.2026.01.014
Duo Zhang , Shuaijie Ji , Zheng Wang , Yanfeng Yang , Heng Yang , Heng Li
Capillary tubes, valued for their large specific surface area and exceptional heat transfer efficiency, are widely used in aerospace, biomedical devices and chemical engineering. Mandrel-free drawing is essential for producing high-performance capillary tubes. In this process, through-thickness deformation is governed by external constraints on the outer surface, whereas the inner surface maintains a free boundary. This creates a radially asymmetric stress field, resulting in uneven deformation through the thickness. When superimposed with process parameter fluctuation, tube blank dimension change, and size effect, the uneven deformation was further exacerbated, making precise control of wall thickness in capillary tube fabrication more challenging. In this work, taking the mandrel-free drawing of GH4169 capillary tubes as the study case, through a series of well-designed simulations and experiments, the coupling effects of process parameters (section reduction, friction coefficient, die angle and sizing band length), tube blank dimension (D/t, the ratio of tube diameter to wall thickness), and size effect factor (t/d, the ratio of wall thickness to grain size) on wall thickness evolution were systemically investigated and revealed. The main findings include: 1) The section reduction, friction coefficient, die angle, and D/t exhibit significant influence on wall thickness evolution of capillary tubes during the mandrel-free drawing, while the sizing band length and t/d exert relatively minor effects. 2) The increase in friction coefficient and die angle raises the deformation gradient and axial stress, making the circumferential compressive strain more easily transform into the axial tensile strain to coordinate deformation, which decreases radial strain and alleviates wall thickness thickening. Conversely, the large section reduction and D/t decrease the deformation gradient and axial stress, resulting in an increase in wall thickness. 3) Due to the separation of the tube from the sizing band, the sizing band length has little influence on the evolution of wall thickness. As the t/d increases, the ratio of axial to radial deformation resistance remains constant, making the evolution of wall thickness independent of the t/d. 4) Based on the above insights, a novel wall thickness control strategy, employing increased friction coefficients (f = 0.12) and large die angles (α = 24°), was proposed to actively regulate the wall thickness of capillary tubes during the mandrel-free drawing process. The drawing experiments indicate that the absolute error of wall thickness was decreased from 0.041 mm to 0.013 mm, achieving a 68.29% improvement in forming accuracy. The developed method in this work will contribute to the high-precision manufacturing of high-performance capillary tubes.
{"title":"Mechanism and control of wall thickness evolution in mandrel-free drawing of capillary tubes","authors":"Duo Zhang , Shuaijie Ji , Zheng Wang , Yanfeng Yang , Heng Yang , Heng Li","doi":"10.1016/j.jmapro.2026.01.014","DOIUrl":"10.1016/j.jmapro.2026.01.014","url":null,"abstract":"<div><div>Capillary tubes, valued for their large specific surface area and exceptional heat transfer efficiency, are widely used in aerospace, biomedical devices and chemical engineering. Mandrel-free drawing is essential for producing high-performance capillary tubes. In this process, through-thickness deformation is governed by external constraints on the outer surface, whereas the inner surface maintains a free boundary. This creates a radially asymmetric stress field, resulting in uneven deformation through the thickness. When superimposed with process parameter fluctuation, tube blank dimension change, and size effect, the uneven deformation was further exacerbated, making precise control of wall thickness in capillary tube fabrication more challenging. In this work, taking the mandrel-free drawing of GH4169 capillary tubes as the study case, through a series of well-designed simulations and experiments, the coupling effects of process parameters (section reduction, friction coefficient, die angle and sizing band length), tube blank dimension (<em>D/t</em>, the ratio of tube diameter to wall thickness), and size effect factor (<em>t/d</em>, the ratio of wall thickness to grain size) on wall thickness evolution were systemically investigated and revealed. The main findings include: 1) The section reduction, friction coefficient, die angle, and <em>D/t</em> exhibit significant influence on wall thickness evolution of capillary tubes during the mandrel-free drawing, while the sizing band length and <em>t/d</em> exert relatively minor effects. 2) The increase in friction coefficient and die angle raises the deformation gradient and axial stress, making the circumferential compressive strain more easily transform into the axial tensile strain to coordinate deformation, which decreases radial strain and alleviates wall thickness thickening. Conversely, the large section reduction and <em>D/t</em> decrease the deformation gradient and axial stress, resulting in an increase in wall thickness. 3) Due to the separation of the tube from the sizing band, the sizing band length has little influence on the evolution of wall thickness. As the <em>t/d</em> increases, the ratio of axial to radial deformation resistance remains constant, making the evolution of wall thickness independent of the <em>t/d</em>. 4) Based on the above insights, a novel wall thickness control strategy, employing increased friction coefficients (<em>f</em> = 0.12) and large die angles (<em>α</em> = 24°), was proposed to actively regulate the wall thickness of capillary tubes during the mandrel-free drawing process. The drawing experiments indicate that the absolute error of wall thickness was decreased from 0.041 mm to 0.013 mm, achieving a 68.29% improvement in forming accuracy. The developed method in this work will contribute to the high-precision manufacturing of high-performance capillary tubes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 28-49"},"PeriodicalIF":6.8,"publicationDate":"2026-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146001831","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 : 2026-01-21DOI: 10.1016/j.jmapro.2026.01.067
Liang Chen , Pu Wang , Jinwen Jin , Shengkai Hu , Zhenjie Du , Jiaquan Zhang
Controlling centerline segregation in high-strength low-alloy (HSLA) steel slabs is essential for producing high-end automotive sheets, as this defect seriously compromises mechanical properties, fatigue resistance, and service life. Therefore, this study quantitatively investigates the mechanisms of dendrite deflection and fragmentation under roller-type electromagnetic stirring (R-EMS), and demonstrates how controlled dendritic growth can effectively mitigate centerline segregation in HSLA steel. The research shows that dendrite deflection exhibits a significant flow-aligned growth characteristic, with deflection primarily occurring in regions with a liquid fraction higher than 0.7, and is regulated by flow velocity: at low velocities, it is dominated by the asymmetry of the concentration boundary layer; at high velocities, it evolves into a competitive mechanism between fluid mechanical force and the solute field. The study further established a quantitative relationship between the critical flow velocity for dendrite fragmentation and its necking degree (characterized by the necking factor β), finding that the critical velocity is inversely proportional to β3, and the critical fragmentation velocity for a dendrite without necking is 0.582 m/s. Regarding process impact, the study found that although excessive stirring can provide a large number of heterogeneous nuclei by promoting dendrite fragmentation, thereby advancing the columnar-to-equiaxed transition (CET), it leads to coarsening of equiaxed crystals and aggravates centerline segregation. By optimizing the stirring configuration—deactivating the first pair of stirrers while maintaining a high current in the second pair—the massive nucleation of equiaxed grains was effectively delayed. This strategy yielded a suitable equiaxed grain ratio of 28.3% and stabilized centerline segregation at level C 0.5, providing a theoretical foundation and a practical strategy for producing HSLA steel slabs.
{"title":"Control of the centerline segregation by manipulating dendritic growth for slab casting of HSLA steel through roller-type electromagnetic stirring","authors":"Liang Chen , Pu Wang , Jinwen Jin , Shengkai Hu , Zhenjie Du , Jiaquan Zhang","doi":"10.1016/j.jmapro.2026.01.067","DOIUrl":"10.1016/j.jmapro.2026.01.067","url":null,"abstract":"<div><div>Controlling centerline segregation in high-strength low-alloy (HSLA) steel slabs is essential for producing high-end automotive sheets, as this defect seriously compromises mechanical properties, fatigue resistance, and service life. Therefore, this study quantitatively investigates the mechanisms of dendrite deflection and fragmentation under roller-type electromagnetic stirring (R-EMS), and demonstrates how controlled dendritic growth can effectively mitigate centerline segregation in HSLA steel. The research shows that dendrite deflection exhibits a significant flow-aligned growth characteristic, with deflection primarily occurring in regions with a liquid fraction higher than 0.7, and is regulated by flow velocity: at low velocities, it is dominated by the asymmetry of the concentration boundary layer; at high velocities, it evolves into a competitive mechanism between fluid mechanical force and the solute field. The study further established a quantitative relationship between the critical flow velocity for dendrite fragmentation and its necking degree (characterized by the necking factor <em>β</em>), finding that the critical velocity is inversely proportional to <em>β</em><sup>3</sup>, and the critical fragmentation velocity for a dendrite without necking is 0.582 m/s. Regarding process impact, the study found that although excessive stirring can provide a large number of heterogeneous nuclei by promoting dendrite fragmentation, thereby advancing the columnar-to-equiaxed transition (CET), it leads to coarsening of equiaxed crystals and aggravates centerline segregation. By optimizing the stirring configuration—deactivating the first pair of stirrers while maintaining a high current in the second pair—the massive nucleation of equiaxed grains was effectively delayed. This strategy yielded a suitable equiaxed grain ratio of 28.3% and stabilized centerline segregation at level C 0.5, providing a theoretical foundation and a practical strategy for producing HSLA steel slabs.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 142-157"},"PeriodicalIF":6.8,"publicationDate":"2026-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036895","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 : 2026-01-21DOI: 10.1016/j.jmapro.2026.01.026
Mohammad Taghian , Ali Pilehvar Meibody , Abdollah Saboori , Luca Iuliano
Powder Bed Fusion (PBF) is a critical enabling technology in metal additive manufacturing (AM) to produce high-performance components deployed in extreme environments, including aerospace, energy, and biomedical applications. However, internal defects, such as lack of fusion porosity, gas-entrapped pores, and keyhole-induced voids continue to impose limitations on structural integrity, fatigue life, and process reliability. Achieving defect-free manufacturing under demanding performance requirements necessitates advanced detection and control strategies. Several recent reviews have addressed either in-situ monitoring techniques or machine-learning-based quality analytics in PBF, but typically in isolation. By contrast, this work provides an integrated review of defect detection across the PBF process chain, with emphasis on in-situ sensing, ex-situ characterization, machine learning-based classification, and mechanistic, numerical, and simulation approaches across micro-, meso-, and macro-scales. Particular focus is placed on computational models that capture critical physical phenomena at different scales, providing insight into defect formation and mitigation in PBF processes. The article also identifies current research gaps and outlines future directions for developing robust defect detection frameworks that support the qualification of AM components for mission-critical and extreme applications. These insights contribute to advancing the state-of-the-art in high-reliability additive manufacturing and accelerating its industrial adoption.
{"title":"Toward closed-loop quality assurance in powder bed fusion additive manufacturing: Defect detection, machine learning, and computational modeling","authors":"Mohammad Taghian , Ali Pilehvar Meibody , Abdollah Saboori , Luca Iuliano","doi":"10.1016/j.jmapro.2026.01.026","DOIUrl":"10.1016/j.jmapro.2026.01.026","url":null,"abstract":"<div><div>Powder Bed Fusion (PBF) is a critical enabling technology in metal additive manufacturing (AM) to produce high-performance components deployed in extreme environments, including aerospace, energy, and biomedical applications. However, internal defects, such as lack of fusion porosity, gas-entrapped pores, and keyhole-induced voids continue to impose limitations on structural integrity, fatigue life, and process reliability. Achieving defect-free manufacturing under demanding performance requirements necessitates advanced detection and control strategies. Several recent reviews have addressed either in-situ monitoring techniques or machine-learning-based quality analytics in PBF, but typically in isolation. By contrast, this work provides an integrated review of defect detection across the PBF process chain, with emphasis on in-situ sensing, ex-situ characterization, machine learning-based classification, and mechanistic, numerical, and simulation approaches across micro-, meso-, and macro-scales. Particular focus is placed on computational models that capture critical physical phenomena at different scales, providing insight into defect formation and mitigation in PBF processes. The article also identifies current research gaps and outlines future directions for developing robust defect detection frameworks that support the qualification of AM components for mission-critical and extreme applications. These insights contribute to advancing the state-of-the-art in high-reliability additive manufacturing and accelerating its industrial adoption.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 50-81"},"PeriodicalIF":6.8,"publicationDate":"2026-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146001852","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 : 2026-01-21DOI: 10.1016/j.jmapro.2026.01.051
Hao Cui , Tao Zhou , Yin Yuan , Cheng Zhang , Feilong Du , Zebin Su , Jing Deng , Pengfei Tian , Zhiguo Feng , Lin He
When milling high-hardness H13 hardened die steel, issues such as excessive milling force and severe tool wear often occur. Research shows that thermally assisted processing can reduce the mechanical stress of the milling process, but it also activates the thermal damage mechanism of the tool and workpiece accordingly. Therefore, the research proposes a multi-energy field processing method for heat-cold source assisted milling and hardened mold steel integrating thermal softening effect (Induction Heating) and clean cooling lubrication effect (Cryogenic Minimum Quantity Lubrication, CMQL). The research first adopted a research method combining simulation with experimental verification to conduct thermal simulation analysis, revealing the control laws of external heat and cold fields on the surface temperature fields of tools and workpieces, and determining the effective milling depth. Afterwards, the heat-cold source multi-energy field synergistic assisted milling experimental platform was built, and the action mechanism of the heat-cold source synergistic working conditions on milling H13 steel was fully revealed. Research show that compared with dry machining, in the HCSAM environment, the main cutting resistance increases by 13.37% and 7.58% respectively when P = 20 kW and 50 kW, while it decreases by 22.3% when P = 80 kW. The application of CMQL enhances heat dissipation from the tool surface, which in turn suppresses the development of a built-up layer and mitigates tool wear. Meanwhile, induction heat will promote the transformation of chip fracture from brittle to ductile, causing the maximum reduction in surface roughness Ra to reach 12.1%. In addition, compared with dry and HCSAM environments (preheating temperatures of 200 °C and 300 °C), the HCSAM environment with a preheating temperature of 550 °C induces grain coarsening and homogenization in the surface and near-surface areas, reduces the work hardening effect, but simultaneously increases the surface residual stress. This study reveals the application potential of heat-cold source synergistic assisted milling (HCSAM) in multi-energy field machining, which can provide an effective solution for high-performance milling of H13 hardened die steel.
{"title":"Research on the mechanism of heat-cold source synergistic assisted milling of hardened die steel","authors":"Hao Cui , Tao Zhou , Yin Yuan , Cheng Zhang , Feilong Du , Zebin Su , Jing Deng , Pengfei Tian , Zhiguo Feng , Lin He","doi":"10.1016/j.jmapro.2026.01.051","DOIUrl":"10.1016/j.jmapro.2026.01.051","url":null,"abstract":"<div><div>When milling high-hardness H13 hardened die steel, issues such as excessive milling force and severe tool wear often occur. Research shows that thermally assisted processing can reduce the mechanical stress of the milling process, but it also activates the thermal damage mechanism of the tool and workpiece accordingly. Therefore, the research proposes a multi-energy field processing method for heat-cold source assisted milling and hardened mold steel integrating thermal softening effect (Induction Heating) and clean cooling lubrication effect (Cryogenic Minimum Quantity Lubrication, CMQL). The research first adopted a research method combining simulation with experimental verification to conduct thermal simulation analysis, revealing the control laws of external heat and cold fields on the surface temperature fields of tools and workpieces, and determining the effective milling depth. Afterwards, the heat-cold source multi-energy field synergistic assisted milling experimental platform was built, and the action mechanism of the heat-cold source synergistic working conditions on milling H13 steel was fully revealed. Research show that compared with dry machining, in the HCSAM environment, the main cutting resistance increases by 13.37% and 7.58% respectively when <em>P</em> = 20 kW and 50 kW, while it decreases by 22.3% when <em>P</em> = 80 kW. The application of CMQL enhances heat dissipation from the tool surface, which in turn suppresses the development of a built-up layer and mitigates tool wear. Meanwhile, induction heat will promote the transformation of chip fracture from brittle to ductile, causing the maximum reduction in surface roughness <em>Ra</em> to reach 12.1%. In addition, compared with dry and HCSAM environments (preheating temperatures of 200 °C and 300 °C), the HCSAM environment with a preheating temperature of 550 °C induces grain coarsening and homogenization in the surface and near-surface areas, reduces the work hardening effect, but simultaneously increases the surface residual stress. This study reveals the application potential of heat-cold source synergistic assisted milling (HCSAM) in multi-energy field machining, which can provide an effective solution for high-performance milling of H13 hardened die steel.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 158-184"},"PeriodicalIF":6.8,"publicationDate":"2026-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036893","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}
扫码关注我们
求助内容：
应助结果提醒方式：
京公网安备 11010802042870号