Journal of Manufacturing Processes最新文献_第5页

Performances of a tailored vegetable oil-based graphene nanofluid in the MQL internal cooling milling

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.063

Ruitao Peng , Jiacheng Shen , Xinzi Tang , Linfeng Zhao , Jiangxiong Gao

This study develops a graphene nanofluid based on vegetable oil, integrated with internal cooling and minimum quantity lubrication (MQL) technology, to enhance cooling and lubrication during the machining of 7075 aluminum alloy. Vegetable oil-based graphene nanofluids with varying mass fractions of graphene nanoplatelets were prepared by a two-step method. Oleic acid was added as a surfactant to improve suspension stability and optimize the viscosity of the base fluid. Thermophysical experiments showed that the 0.5 wt% graphene nanofluid exhibited a 23.57 % higher thermal conductivity compared to pure vegetable oil, while maintaining lower viscosity for better cooling performance. In tribological tests, graphene significantly reduced the friction coefficient (6.80 %–17.04 %) and wear, with XPS analysis confirming the formation of a stable carbon film that enhanced wear resistance. MQL milling experiments revealed that the optimized nanofluid reduced cutting temperatures by 11.31 %–20.98 %, cutting forces by 6.75 %–12.83 %, and surface roughness by 7.35 %–20.33 %, while extending tool life by up to 52.9 %. A sustainability evaluation further highlighted the superior environmental compatibility, reduced maintenance demands, improved operator safety, and cost-effectiveness of the nanofluid-MQL compared to conventional cooling methods. These findings demonstrate that the optimized graphene nanofluid significantly enhances machining efficiency, tool life, surface quality, and sustainability.

{"title":"Performances of a tailored vegetable oil-based graphene nanofluid in the MQL internal cooling milling","authors":"Ruitao Peng , Jiacheng Shen , Xinzi Tang , Linfeng Zhao , Jiangxiong Gao","doi":"10.1016/j.jmapro.2024.12.063","DOIUrl":"10.1016/j.jmapro.2024.12.063","url":null,"abstract":"<div><div>This study develops a graphene nanofluid based on vegetable oil, integrated with internal cooling and minimum quantity lubrication (MQL) technology, to enhance cooling and lubrication during the machining of 7075 aluminum alloy. Vegetable oil-based graphene nanofluids with varying mass fractions of graphene nanoplatelets were prepared by a two-step method. Oleic acid was added as a surfactant to improve suspension stability and optimize the viscosity of the base fluid. Thermophysical experiments showed that the 0.5 wt% graphene nanofluid exhibited a 23.57 % higher thermal conductivity compared to pure vegetable oil, while maintaining lower viscosity for better cooling performance. In tribological tests, graphene significantly reduced the friction coefficient (6.80 %–17.04 %) and wear, with XPS analysis confirming the formation of a stable carbon film that enhanced wear resistance. MQL milling experiments revealed that the optimized nanofluid reduced cutting temperatures by 11.31 %–20.98 %, cutting forces by 6.75 %–12.83 %, and surface roughness by 7.35 %–20.33 %, while extending tool life by up to 52.9 %. A sustainability evaluation further highlighted the superior environmental compatibility, reduced maintenance demands, improved operator safety, and cost-effectiveness of the nanofluid-MQL compared to conventional cooling methods. These findings demonstrate that the optimized graphene nanofluid significantly enhances machining efficiency, tool life, surface quality, and sustainability.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 814-831"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131739","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Connecting texture development to die design in extruded flat products

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.078

Fabian Esterl , Maria Nienaber , Jan Bohlen , Noomane Ben Khalifa

This study investigates the local texture modification of two magnesium alloys (AZ31 and ZX10) and an aluminum alloy (AA6082) based on changes in the die design. For this purpose, a conventional flat die and a modified die, which has been additively manufactured to allow for a significant modification of the material flow, are investigated. Extrusion tests are carried out, followed by a comprehensive examination of the microstructure and local texture development. These experimental results are complemented by finite element analysis of the state variable distribution in the cross section of the extruded band. The results demonstrate that the texture change is connected to the strain path and can therefore be controlled based on the die design. This equally applies to all of the investigated alloys, despite their differences in crystallographic deformation and recrystallization behavior. Accordingly, a rotation of the dominant texture components about ND at the edge of the band of approximately 40°, 45°, and 20° is observed for AZ31, ZX10, and AA6082, respectively. These findings correlate well with the difference in rotation around ND between the dies of 39°, which is calculated numerically based on the deformation gradient tensor. Furthermore, AZ31 and ZX10 demonstrate a broadening of the basal planes in the TD when extruded with the modified die, which can be related to the increased shear strains in the ED/TD plane over the entire width of the band. For ZX10 specifically, a completely different texture is generated due to the combination of the broadened basal planes in TD, the rotation of the dominant texture component around ND, and its tilt in ED, characteristic of extruded Ca-containing Mg-alloys. The investigation on AA6082 further illustrates the importance of the effective temperature and strain rate in the forming zone for its texture development. While no significant change in the microstructure is evident, the increased heat dissipation and smoothed introduction of dislocations during extrusion with the modified die correlates with a transition from Cube to Goss as the dominant texture component.

{"title":"Connecting texture development to die design in extruded flat products","authors":"Fabian Esterl , Maria Nienaber , Jan Bohlen , Noomane Ben Khalifa","doi":"10.1016/j.jmapro.2024.12.078","DOIUrl":"10.1016/j.jmapro.2024.12.078","url":null,"abstract":"<div><div>This study investigates the local texture modification of two magnesium alloys (AZ31 and ZX10) and an aluminum alloy (AA6082) based on changes in the die design. For this purpose, a conventional flat die and a modified die, which has been additively manufactured to allow for a significant modification of the material flow, are investigated. Extrusion tests are carried out, followed by a comprehensive examination of the microstructure and local texture development. These experimental results are complemented by finite element analysis of the state variable distribution in the cross section of the extruded band. The results demonstrate that the texture change is connected to the strain path and can therefore be controlled based on the die design. This equally applies to all of the investigated alloys, despite their differences in crystallographic deformation and recrystallization behavior. Accordingly, a rotation of the dominant texture components about ND at the edge of the band of approximately 40°, 45°, and 20° is observed for AZ31, ZX10, and AA6082, respectively. These findings correlate well with the difference in rotation around ND between the dies of 39°, which is calculated numerically based on the deformation gradient tensor. Furthermore, AZ31 and ZX10 demonstrate a broadening of the basal planes in the TD when extruded with the modified die, which can be related to the increased shear strains in the ED/TD plane over the entire width of the band. For ZX10 specifically, a completely different texture is generated due to the combination of the broadened basal planes in TD, the rotation of the dominant texture component around ND, and its tilt in ED, characteristic of extruded Ca-containing Mg-alloys. The investigation on AA6082 further illustrates the importance of the effective temperature and strain rate in the forming zone for its texture development. While no significant change in the microstructure is evident, the increased heat dissipation and smoothed introduction of dislocations during extrusion with the modified die correlates with a transition from Cube to Goss as the dominant texture component.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 891-903"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131772","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}

引用次数: 0

Graphical compensation of area coverage and stitching accuracy for galvanometric laser texturing on spherical surface

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.014

Xu Chen, Youmin Rong, Ranwu Yang, Miaozheng Wang, Yuxuan Tao, Yu Huang

This paper presents the graphical compensation of area coverage and stitching accuracy for galvanometric laser texturing on spherical surface to improve the area coverage and stitching accuracy. The spherical surface is divided into partitions based on the spherical central angle. The sphere is approximated as a UV polyhedron to examine the effect of the spherical central angle on area coverage and stitching accuracy. Based on Spherical Triangular Area Coordinate Systems (STACs), this paper proposes Single Spherical Polygonal Area Coordinate Systems (SSPACs) and Multi Spherical Triangular Area Coordinates Systems (MSTACs). The benefits of MSTACs in improving area coverage and stitching accuracy are demonstrated. Furthermore, a method for repainting bitmaps using parallel projection, contour detection, and pixel upsampling is proposed. This method reconstructs the compensated discrete pixel points into a filled bitmap. Processing on a 30 mm diameter hemisphere, the average of Relative Area Mean (RA Mean) was improved by 2.02 %, and the average of Zone Standardized Compactness Mean Absolute Error (ZSC MAE) was reduced by 73.33 % after compensation with MSTACs. The Mean Absolute Deviation (MAD) of the stitching error between the cambered patches decreased from 88.95 μm to 4.72 μm (by 94.69 %). The Root Mean Square (RMS) also reduced from 111.77 μm to 5.62 μm (a reduction of 94.97 %), and the Standard Deviation (SD) decreased from 67.9 μm to 4.39 μm (a reduction of 93.54 %). Furthermore, this paper proposes that a smaller spherical central angle from the center of the cambered patch to stitching results in higher area coverage and lower stitching errors, thereby demonstrating the impact of the proposed spherical surface partition. Therefore, the proposed graphic processing method is practical for improving area coverage and reducing stitching errors in spherical laser texturing.

{"title":"Graphical compensation of area coverage and stitching accuracy for galvanometric laser texturing on spherical surface","authors":"Xu Chen, Youmin Rong, Ranwu Yang, Miaozheng Wang, Yuxuan Tao, Yu Huang","doi":"10.1016/j.jmapro.2024.12.014","DOIUrl":"10.1016/j.jmapro.2024.12.014","url":null,"abstract":"<div><div>This paper presents the graphical compensation of area coverage and stitching accuracy for galvanometric laser texturing on spherical surface to improve the area coverage and stitching accuracy. The spherical surface is divided into partitions based on the spherical central angle. The sphere is approximated as a UV polyhedron to examine the effect of the spherical central angle on area coverage and stitching accuracy. Based on Spherical Triangular Area Coordinate Systems (STACs), this paper proposes Single Spherical Polygonal Area Coordinate Systems (SSPACs) and Multi Spherical Triangular Area Coordinates Systems (MSTACs). The benefits of MSTACs in improving area coverage and stitching accuracy are demonstrated. Furthermore, a method for repainting bitmaps using parallel projection, contour detection, and pixel upsampling is proposed. This method reconstructs the compensated discrete pixel points into a filled bitmap. Processing on a 30 mm diameter hemisphere, the average of Relative Area Mean (RA Mean) was improved by 2.02 %, and the average of Zone Standardized Compactness Mean Absolute Error (ZSC MAE) was reduced by 73.33 % after compensation with MSTACs. The Mean Absolute Deviation (MAD) of the stitching error between the cambered patches decreased from 88.95 μm to 4.72 μm (by 94.69 %). The Root Mean Square (RMS) also reduced from 111.77 μm to 5.62 μm (a reduction of 94.97 %), and the Standard Deviation (SD) decreased from 67.9 μm to 4.39 μm (a reduction of 93.54 %). Furthermore, this paper proposes that a smaller spherical central angle from the center of the cambered patch to stitching results in higher area coverage and lower stitching errors, thereby demonstrating the impact of the proposed spherical surface partition. Therefore, the proposed graphic processing method is practical for improving area coverage and reducing stitching errors in spherical laser texturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 14-28"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131878","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Comparative study on the reinforcement effects of WC and TiC in the laser cladding layer of Ti-6Al-4V alloy

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.076

Zhanzheng Fan , Weibin Ren , Weihao Zuo , Yujiang Wang

Addressing the unclear evolutionary process and characteristics of TiC and WC morphologies in Ti-6Al-4V (TC4) alloy cladding layers, as well as the unelucidated mechanisms and behaviors of their strengthening precipitates, we prepared x wt% TiC + (1-x) wt% TC4 cladding layers and x wt% WC + (1-x) wt% TC4 cladding layers (x = 10, 15, and 20) on the surface of TC4 alloy using an optimized laser cladding process. We analyzed and compared the influence of the two types of carbide reinforcements on the phase composition of the cladding layers, and elucidated the strengthening mechanisms, precipitation behavior and characteristics, as well as the presence and distribution of the two carbide reinforcements within the cladding layers. The study also compared the effects of varying reinforcement contents on the microhardness, wear resistance, and electrochemical corrosion resistance of the cladding layers. The experimental results show that WC has a significant impact on the phase composition of the cladding. In the TiC cladding layer, only the TiC phase is newly added, while in the WC cladding layer, new phases such as WC, W₂C, W and (Ti, W)C_1-x are formed. TiC exists mainly in two forms, molten and unmelted, in the cladding. The molten TiC precipitates from the molten pool in petal-like and granular forms and is evenly distributed in the cladding. WC mainly exists in an unmelted state in the cladding and is deposited in large quantities at the bottom of the cladding. The average microhardness of the 20 wt% TiC cladding is 92 % of that of the 20 wt% WC cladding. However, its friction and wear rate is only 41 % of that of the latter, and its electrochemical corrosion rate is merely 20 % of that of the 20 wt% WC cladding. We recommend using a 20 wt% TiC +80 wt% TC4 ratio under a laser power of 2500 W, a scanning speed of 5 mm/s, and a powder feeding rate of 30 g/min to prepare a cladding layer with more excellent performance.

{"title":"Comparative study on the reinforcement effects of WC and TiC in the laser cladding layer of Ti-6Al-4V alloy","authors":"Zhanzheng Fan , Weibin Ren , Weihao Zuo , Yujiang Wang","doi":"10.1016/j.jmapro.2024.12.076","DOIUrl":"10.1016/j.jmapro.2024.12.076","url":null,"abstract":"<div><div>Addressing the unclear evolutionary process and characteristics of TiC and WC morphologies in Ti-6Al-4V (TC4) alloy cladding layers, as well as the unelucidated mechanisms and behaviors of their strengthening precipitates, we prepared x wt% TiC + (1-x) wt% TC4 cladding layers and x wt% WC + (1-x) wt% TC4 cladding layers (x = 10, 15, and 20) on the surface of TC4 alloy using an optimized laser cladding process. We analyzed and compared the influence of the two types of carbide reinforcements on the phase composition of the cladding layers, and elucidated the strengthening mechanisms, precipitation behavior and characteristics, as well as the presence and distribution of the two carbide reinforcements within the cladding layers. The study also compared the effects of varying reinforcement contents on the microhardness, wear resistance, and electrochemical corrosion resistance of the cladding layers. The experimental results show that WC has a significant impact on the phase composition of the cladding. In the TiC cladding layer, only the TiC phase is newly added, while in the WC cladding layer, new phases such as WC, W<sub>2</sub>C, W and (Ti, W)C<sub>1-x</sub> are formed. TiC exists mainly in two forms, molten and unmelted, in the cladding. The molten TiC precipitates from the molten pool in petal-like and granular forms and is evenly distributed in the cladding. WC mainly exists in an unmelted state in the cladding and is deposited in large quantities at the bottom of the cladding. The average microhardness of the 20 wt% TiC cladding is 92 % of that of the 20 wt% WC cladding. However, its friction and wear rate is only 41 % of that of the latter, and its electrochemical corrosion rate is merely 20 % of that of the 20 wt% WC cladding. We recommend using a 20 wt% TiC +80 wt% TC4 ratio under a laser power of 2500 W, a scanning speed of 5 mm/s, and a powder feeding rate of 30 g/min to prepare a cladding layer with more excellent performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 589-602"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131927","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

An intelligent prediction paradigm for milling tool parameters design based on multi-task tabular data deep transfer learning integrating physical knowledge

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.072

Caihua Hao , Weiye Li , Xinyong Mao , Songping He , Bin Li , Hongqi Liu , Fangyu Peng , Chaochao Qiu

Industries such as 3C are increasingly incorporating titanium alloy structural components, leading to a significant demand for machining tools. The geometric parameters of these tools are crucial for their lifespan. However, the current reliance on manual design and iterative processes hampers rapid and high-quality tool design, adversely affecting product quality, production speed, and costs. To tackle this industrial challenge, it is essential to explore intelligent prediction paradigms for geometric parameter design. Achieving end-to-end prediction of multiple geometric parameters for cutting tools remains a complex task, with limited research on small-sample multi-task tabular data. This article proposes a novel deep transfer learning framework (Phy-MTDTL) for multi-task tabular data, integrating two pre-training and transfer paradigms while incorporating physical knowledge. This approach addresses challenges in multi-task prediction, small sample sizes, and the interpretability of industrial tabular data modeling. The framework introduces an innovative paradigm for high-precision and high-qualification-rate intelligent prediction of multiple geometric parameters, paving the way for new research directions in cutting tool design. The integration of physical knowledge is reflected in three aspects: dataset, model structure, and evaluation indicators, enhancing the interpretability and credibility of the proposed method. Experimental results demonstrate the framework's effectiveness, showing significantly superior prediction accuracy and physical pass rates exceeding 90 % across five different geometric parameter prediction tasks compared to current transfer learning models. Additionally, the incorporation of physical knowledge enhances transfer prediction performance for small-sample tabular data. These results indicate that the study has significant industrial applicability and value.

{"title":"An intelligent prediction paradigm for milling tool parameters design based on multi-task tabular data deep transfer learning integrating physical knowledge","authors":"Caihua Hao , Weiye Li , Xinyong Mao , Songping He , Bin Li , Hongqi Liu , Fangyu Peng , Chaochao Qiu","doi":"10.1016/j.jmapro.2024.12.072","DOIUrl":"10.1016/j.jmapro.2024.12.072","url":null,"abstract":"<div><div>Industries such as 3C are increasingly incorporating titanium alloy structural components, leading to a significant demand for machining tools. The geometric parameters of these tools are crucial for their lifespan. However, the current reliance on manual design and iterative processes hampers rapid and high-quality tool design, adversely affecting product quality, production speed, and costs. To tackle this industrial challenge, it is essential to explore intelligent prediction paradigms for geometric parameter design. Achieving end-to-end prediction of multiple geometric parameters for cutting tools remains a complex task, with limited research on small-sample multi-task tabular data. This article proposes a novel deep transfer learning framework (Phy-MTDTL) for multi-task tabular data, integrating two pre-training and transfer paradigms while incorporating physical knowledge. This approach addresses challenges in multi-task prediction, small sample sizes, and the interpretability of industrial tabular data modeling. The framework introduces an innovative paradigm for high-precision and high-qualification-rate intelligent prediction of multiple geometric parameters, paving the way for new research directions in cutting tool design. The integration of physical knowledge is reflected in three aspects: dataset, model structure, and evaluation indicators, enhancing the interpretability and credibility of the proposed method. Experimental results demonstrate the framework's effectiveness, showing significantly superior prediction accuracy and physical pass rates exceeding 90 % across five different geometric parameter prediction tasks compared to current transfer learning models. Additionally, the incorporation of physical knowledge enhances transfer prediction performance for small-sample tabular data. These results indicate that the study has significant industrial applicability and value.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 998-1020"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132047","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Study on temperature control and bonding properties of Ti/Al composite plates rolled by differential temperature rolling with mobile induction heating

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.054

Boxing Gao, Yanchao Hao, Chao Yu, Yuhua Wu, Hong Xiao

To address the issue of non-uniform temperature distribution in titanium plates during electromagnetic induction heating, this study proposes an innovative coil structure designed to enhance induced eddy current density in the center of the titanium plate. By employing moving induction heating, a uniform temperature distribution across the plate width is achieved. By conducting differential temperature rolling composite experiments, titanium/aluminum composite plates with high bonding strength and excellent flatness can be prepared. The results show that by moving induction heating, high and low temperature regions during stationary heating can complement each other, thereby promoting uniform distribution of temperature in the width direction of the titanium plate. When the titanium plate is heated to 800 °C and room-temperature aluminum plate rolled, greater rolling reduction improved interfacial bonding strength, reaching an interfacial shear strength of 117.3 MPa at a 38.7 % reduction. Additionally, increased reduction facilitated sub-grain and grain refinement at the interface, enhancing the plasticity and toughness of the titanium layer, mitigating dislocation movement, and reducing interfacial stress concentration. Furthermore, brittle precipitates of Al₉Si formed in the aluminum matrix near the bonding interface, resulting in shear fractures within the aluminum matrix near the interface.

{"title":"Study on temperature control and bonding properties of Ti/Al composite plates rolled by differential temperature rolling with mobile induction heating","authors":"Boxing Gao, Yanchao Hao, Chao Yu, Yuhua Wu, Hong Xiao","doi":"10.1016/j.jmapro.2024.12.054","DOIUrl":"10.1016/j.jmapro.2024.12.054","url":null,"abstract":"<div><div>To address the issue of non-uniform temperature distribution in titanium plates during electromagnetic induction heating, this study proposes an innovative coil structure designed to enhance induced eddy current density in the center of the titanium plate. By employing moving induction heating, a uniform temperature distribution across the plate width is achieved. By conducting differential temperature rolling composite experiments, titanium/aluminum composite plates with high bonding strength and excellent flatness can be prepared. The results show that by moving induction heating, high and low temperature regions during stationary heating can complement each other, thereby promoting uniform distribution of temperature in the width direction of the titanium plate. When the titanium plate is heated to 800 °C and room-temperature aluminum plate rolled, greater rolling reduction improved interfacial bonding strength, reaching an interfacial shear strength of 117.3 MPa at a 38.7 % reduction. Additionally, increased reduction facilitated sub-grain and grain refinement at the interface, enhancing the plasticity and toughness of the titanium layer, mitigating dislocation movement, and reducing interfacial stress concentration. Furthermore, brittle precipitates of Al<sub>9</sub>Si formed in the aluminum matrix near the bonding interface, resulting in shear fractures within the aluminum matrix near the interface.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 348-359"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132199","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Eddy current testing and monitoring in metal additive manufacturing: A review

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.033

Medad C.C. Monu, Josiah C. Chekotu, Dermot Brabazon

In-situ process monitoring and sensing play an indispensable role in ensuring the quality and repeatability of additively manufactured components, as well as providing a means for optimizing process parameters and increasing the uptime of additive manufacturing (AM) equipment. This review paper offers an overview of the current state-of-the-art in ex-situ and in-situ assessments of AM part quality using the eddy current-based non-destructive testing technique. The adoption of eddy current testing (ECT) for both ex-situ and in-situ AM assessments is still in its infancy. This review paper begins by providing a concise description of the ECT technique and parameters using select case studies on conventionally manufactured components. The implementation of ECT for metal AM part quality assessment is discussed using case studies on powder bed fusion, direct energy deposition, and subtractive/additive hybrid AM components. Additionally, this paper presents the challenges and requirements for further development in this area towards developing closed-loop smart control and AM digital twins. These advancements hold the key to unlocking the full potential of metal AM techniques, thereby enabling more efficient and sustainable manufacturing practices.

{"title":"Eddy current testing and monitoring in metal additive manufacturing: A review","authors":"Medad C.C. Monu, Josiah C. Chekotu, Dermot Brabazon","doi":"10.1016/j.jmapro.2024.12.033","DOIUrl":"10.1016/j.jmapro.2024.12.033","url":null,"abstract":"<div><div><em>In-situ</em> process monitoring and sensing play an indispensable role in ensuring the quality and repeatability of additively manufactured components, as well as providing a means for optimizing process parameters and increasing the uptime of additive manufacturing (AM) equipment. This review paper offers an overview of the current state-of-the-art in <em>ex-situ</em> and <em>in-situ</em> assessments of AM part quality using the eddy current-based non-destructive testing technique. The adoption of eddy current testing (ECT) for both <em>ex-situ</em> and <em>in-situ</em> AM assessments is still in its infancy. This review paper begins by providing a concise description of the ECT technique and parameters using select case studies on conventionally manufactured components. The implementation of ECT for metal AM part quality assessment is discussed using case studies on powder bed fusion, direct energy deposition, and subtractive/additive hybrid AM components. Additionally, this paper presents the challenges and requirements for further development in this area towards developing closed-loop smart control and AM digital twins. These advancements hold the key to unlocking the full potential of metal AM techniques, thereby enabling more efficient and sustainable manufacturing practices.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 558-588"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143131928","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}

引用次数: 0

A novel multi-DOF point envelope forming process for manufacturing thin-walled components

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2025.01.017

Xinghui Han , Faxing Shi , Wuhao Zhuang , Lin Hua , Fangyan Zheng , Man Xu

Thin-walled components are widely used in aerospace, ship and automotive industries owing to the light weight advantages. Rotary forging is an advanced process for manufacturing thin-walled components owing to its local deformation mode and small forming force. However, for large scale thin-walled components, the forming force in rotary forging becomes larger because of the larger contacting area between dies and thin-walled component (The contact between dies and thin-walled component is line contact in theory). Therefore, it is necessary to further reduce the forming force in rotary forging so as to improve its process limits. This paper proposes a novel multi-DOF point envelope forming process for manufacturing thin-walled components, in which the contacting area between dies and thin-walled component is significantly reduced and consequently the forming force is significantly reduced (The contact between dies and thin-walled component is point contact in theory). Firstly, the principle of multi-DOF point envelope forming process is proposed. Secondly, the design methods for envelope die geometry and motion are developed. Thirdly, a FE model for multi-DOF point envelope forming process of a thin-walled component is established. Through the FE simulation, the evolution laws of plastic strain, metal flow velocity, geometry shape and forming force are revealed. Finally, a novel multi-DOF envelope forming equipment is developed and the multi-DOF point envelope forming experiment of a thin-walled component is carried out. The simulation and experimental results indicate that the proposed multi-DOF point envelope forming process and equipment are suitable for manufacturing thin-walled components and the forming force can be significantly reduced compared with rotary forging.

{"title":"A novel multi-DOF point envelope forming process for manufacturing thin-walled components","authors":"Xinghui Han , Faxing Shi , Wuhao Zhuang , Lin Hua , Fangyan Zheng , Man Xu","doi":"10.1016/j.jmapro.2025.01.017","DOIUrl":"10.1016/j.jmapro.2025.01.017","url":null,"abstract":"<div><div>Thin-walled components are widely used in aerospace, ship and automotive industries owing to the light weight advantages. Rotary forging is an advanced process for manufacturing thin-walled components owing to its local deformation mode and small forming force. However, for large scale thin-walled components, the forming force in rotary forging becomes larger because of the larger contacting area between dies and thin-walled component (The contact between dies and thin-walled component is line contact in theory). Therefore, it is necessary to further reduce the forming force in rotary forging so as to improve its process limits. This paper proposes a novel multi-DOF point envelope forming process for manufacturing thin-walled components, in which the contacting area between dies and thin-walled component is significantly reduced and consequently the forming force is significantly reduced (The contact between dies and thin-walled component is point contact in theory). Firstly, the principle of multi-DOF point envelope forming process is proposed. Secondly, the design methods for envelope die geometry and motion are developed. Thirdly, a FE model for multi-DOF point envelope forming process of a thin-walled component is established. Through the FE simulation, the evolution laws of plastic strain, metal flow velocity, geometry shape and forming force are revealed. Finally, a novel multi-DOF envelope forming equipment is developed and the multi-DOF point envelope forming experiment of a thin-walled component is carried out. The simulation and experimental results indicate that the proposed multi-DOF point envelope forming process and equipment are suitable for manufacturing thin-walled components and the forming force can be significantly reduced compared with rotary forging.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 1082-1095"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132040","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Analytical model for corrugated rolling of composite plates considering the shear effect

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2025.01.025

Yuanming Liu , Jun Su , Dongping He , Pingju Hao , Yanxiao Liu , Zhenhua Wang , Tao Wang

The corrugated rolling process is widely applied in composite plate manufacturing due to its good plate quality and high bonding strength. In accordance with the slab method, a mathematical analytical model of corrugated rolling is presented in this paper. A new and more accurate assumption is adopted, that is, the uneven distribution of shear stress on the vertical side of the slab in the deformation zone is considered. The analytical solution for the roll separating force model is derived by establishing the differential equation for the force balance of the deformation unit within the deformation zone, incorporating the yield condition, and utilizing the geometric and constitutive equations. The determination of the integral constant is based on the boundary condition. In addition, the experimental value and the finite element simulation value are compared with the fluctuating roll separating force obtained by the model to verify the accuracy of the model. The error of the model is within a margin of 2.9 %. In this model, the distributions of particular rolling pressure and particular lateral stress for composite plates and rolls can be conveniently calculated. In addition, different ratio of the friction factors and the ratio of the shear yield stress are discussed in relation to its distribution. The effect of rolling parameters on the fluctuating roll separating force and the position of the lower neutral point are also investigated, such as the reduction ratio, the ratio of the shear yield stress, and the ratio of the friction factor. A fluctuating roll separation force and deformation parameter analytical model can be applied to corrugated rolling to analyze its characteristics. It is important for accurate roll separating force control, as well as for optimizing the rolling process.

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引用次数: 0

Mitigating springback defects in variable-curvature elliptical panels through multi-pass roll forming optimised by the UOSDM method

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-31 DOI: 10.1016/j.jmapro.2024.12.058

Chunjian Su , Xuemeng Li , Kai Zhang , Hui Jiang , Shumei Lou , Rui Wang , Wei Min Huang , Jie Sun

The bending angle is a critical parameter in the roll-forming process. An appropriate bending angle distribution can enhance the forming quality of sheets and minimize defects. However, research on the bending angles and mechanisms of variable curvature surface plates remains in the preliminary stages of exploration. Therefore, this study focuses on long plates with variable-curvature elliptical surfaces, and a generalized bending angle assignment formula (IEBAF) for curved plates is derived based on the standing edge end projections. Subsequently, a bending angle distribution method (the universal optimised springback defect method, UOSDM) is proposed to address springback defects in variable-curvature elliptical plates. The mechanisms of forming plasticity and its influence on the quality of the formed sheets are investigated through finite element simulations and experimental verifications employing various bending angle formation methods. The results indicate that during the multi-pass roll forming process of variable-curvature elliptical panels using the UOSDM method, the reductions in stress and strain before and after unloading are 6 MPa and 0.02, respectively. This method exhibits minimal data error and achieves optimal forming effects. The experimental and simulated springback angles of the panels fabricated using the UOSDM roll bending method are 1.42° and 1.34°, respectively. Compared to other methods, the springback value is minimized, resulting in the best final forming effect of the panels. The simulation closely matches experimental data, validating the model's accuracy and the proposed method's effectiveness. This research offers significant theoretical foundations and technical support for the precise forming of variable-curvature surface components.

{"title":"Mitigating springback defects in variable-curvature elliptical panels through multi-pass roll forming optimised by the UOSDM method","authors":"Chunjian Su , Xuemeng Li , Kai Zhang , Hui Jiang , Shumei Lou , Rui Wang , Wei Min Huang , Jie Sun","doi":"10.1016/j.jmapro.2024.12.058","DOIUrl":"10.1016/j.jmapro.2024.12.058","url":null,"abstract":"<div><div>The bending angle is a critical parameter in the roll-forming process. An appropriate bending angle distribution can enhance the forming quality of sheets and minimize defects. However, research on the bending angles and mechanisms of variable curvature surface plates remains in the preliminary stages of exploration. Therefore, this study focuses on long plates with variable-curvature elliptical surfaces, and a generalized bending angle assignment formula (IEBAF) for curved plates is derived based on the standing edge end projections. Subsequently, a bending angle distribution method (the universal optimised springback defect method, UOSDM) is proposed to address springback defects in variable-curvature elliptical plates. The mechanisms of forming plasticity and its influence on the quality of the formed sheets are investigated through finite element simulations and experimental verifications employing various bending angle formation methods. The results indicate that during the multi-pass roll forming process of variable-curvature elliptical panels using the UOSDM method, the reductions in stress and strain before and after unloading are 6 MPa and 0.02, respectively. This method exhibits minimal data error and achieves optimal forming effects. The experimental and simulated springback angles of the panels fabricated using the UOSDM roll bending method are 1.42° and 1.34°, respectively. Compared to other methods, the springback value is minimized, resulting in the best final forming effect of the panels. The simulation closely matches experimental data, validating the model's accuracy and the proposed method's effectiveness. This research offers significant theoretical foundations and technical support for the precise forming of variable-curvature surface components.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 235-248"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132264","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0