Pub Date : 2024-10-04DOI: 10.1016/j.jmapro.2024.09.044
Yue Cao , Quan Zhou , Wei Yuan , Qiang Ye , Dan Popa , YuMing Zhang
This paper reviews and analyzes the recent progress in human-robot collaborative (HRC) technologies that enhance assembly and welding processes. It focuses on how the HRC approach helps improve assembly and welding productivity and quality, while enabling complex process operations that cannot be accomplished by humans or robots/machines alone. It also discusses the basic elements in HRC approaches, including (1) human sensors, (2) signal processing for extraction of human intent from sensors, (3) presentation of information to the human for their reaction, obtained from environmental sensors that monitor the environment, machines, and processes, and (4) interface control, which manages how information is presented to the human, what reactions are expected from the human, and what needs to be presented next. Finally, it summarizes the state-of-the-art in the major elements and application accomplishments, identifies challenges for greater benefits, and proposes directions to address these challenges.
{"title":"Human-robot collaborative assembly and welding: A review and analysis of the state of the art","authors":"Yue Cao , Quan Zhou , Wei Yuan , Qiang Ye , Dan Popa , YuMing Zhang","doi":"10.1016/j.jmapro.2024.09.044","DOIUrl":"10.1016/j.jmapro.2024.09.044","url":null,"abstract":"<div><div>This paper reviews and analyzes the recent progress in human-robot collaborative (HRC) technologies that enhance assembly and welding processes. It focuses on how the HRC approach helps improve assembly and welding productivity and quality, while enabling complex process operations that cannot be accomplished by humans or robots/machines alone. It also discusses the basic elements in HRC approaches, including (1) human sensors, (2) signal processing for extraction of human intent from sensors, (3) presentation of information to the human for their reaction, obtained from environmental sensors that monitor the environment, machines, and processes, and (4) interface control, which manages how information is presented to the human, what reactions are expected from the human, and what needs to be presented next. Finally, it summarizes the state-of-the-art in the major elements and application accomplishments, identifies challenges for greater benefits, and proposes directions to address these challenges.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1388-1403"},"PeriodicalIF":6.1,"publicationDate":"2024-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423730","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 : 2024-10-03DOI: 10.1016/j.jmapro.2024.09.054
Zehong Lu , Guanying Huo , Xin Jiang
Singularity in five-axis machining is a series of positions where the rotation axis is parallel to the tool direction. At the singularity points, the rotary axis is unpredictable and might rotate abruptly, which causes a large nonlinear error and damages the machine tool. For the machining at singularity points, it is desirable first to reduce the nonlinear error to avoid gouge and then limit the axis velocity to protect the machine tools. This paper presents a novel approach to avoid gouge and limit the axis velocity at singularity. In the gouge avoiding, an inverse kinematic function around singularity (IKS) is proposed, and the NC program is optimized by the G-code blocks interpolating, which preserves the original G-code and reduces the nonlinear errors. In the limitation of the axis velocity, a concept of maximum allowed feedrate (MAF) is introduced, and the angular velocity of each axis at the singularity point is limited by interpolating the F-code (feedrate command) to each G-code block. In the end, simulations and experiments' results demonstrate the effectiveness of the NC program interpolation method.
五轴加工中的奇点是指旋转轴与刀具方向平行的一系列位置。在奇点处，旋转轴的旋转是不可预测的，可能会突然旋转，从而导致较大的非线性误差并损坏机床。对于奇点处的加工，最好首先减小非线性误差以避免刨削，然后限制轴速度以保护机床。本文提出了一种在奇点处避免刨削和限制轴速的新方法。在避免刨削方面，提出了奇点附近的反运动学函数（IKS），并通过 G 代码块插值对 NC 程序进行了优化，从而保留了原始 G 代码并减少了非线性误差。在限制轴速度方面，引入了最大允许进给速度（MAF）的概念，通过将 F 代码（进给速度指令）插值到各 G 代码块来限制奇点处各轴的角速度。最后，模拟和实验结果证明了数控程序插值方法的有效性。
{"title":"A new method to minimize the five-axis CNC machining error around singular points based on NC program interpolation","authors":"Zehong Lu , Guanying Huo , Xin Jiang","doi":"10.1016/j.jmapro.2024.09.054","DOIUrl":"10.1016/j.jmapro.2024.09.054","url":null,"abstract":"<div><div>Singularity in five-axis machining is a series of positions where the rotation axis is parallel to the tool direction. At the singularity points, the rotary axis is unpredictable and might rotate abruptly, which causes a large nonlinear error and damages the machine tool. For the machining at singularity points, it is desirable first to reduce the nonlinear error to avoid gouge and then limit the axis velocity to protect the machine tools. This paper presents a novel approach to avoid gouge and limit the axis velocity at singularity. In the gouge avoiding, an <em>inverse kinematic function around singularity</em> (IKS) is proposed, and the NC program is optimized by the G-code blocks interpolating, which preserves the original G-code and reduces the nonlinear errors. In the limitation of the axis velocity, a concept of maximum allowed feedrate (MAF) is introduced, and the angular velocity of each axis at the singularity point is limited by interpolating the F-code (feedrate command) to each G-code block. In the end, simulations and experiments' results demonstrate the effectiveness of the NC program interpolation method.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1263-1281"},"PeriodicalIF":6.1,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423738","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}
Vacuum diffusion bonding of TC4 titanium alloy (TC4) to T2 copper (T2) using nickel foil as transition interlayer was explored. Ti3Ni, Ti2Ni, TiNi, AlNi2Ti and TiNi3 phases arose at the TC4/Ni bonded interface, and Cu-Ni solid solution appeared in the Ni/T2 interface. Thereinto, AlNi2Ti was a kind of discontinuous nano precipitated phase, which distributed between TiNi and TiNi3 phases. The crystallographic orientations of Ti2Ni, TiNi, AlNi2Ti and TiNi3 phases were (201), (020), () and (031), respectively. The interplanar spacing of (031), () and (020) was correspondingly d(031) = 0.144 nm, = 0.275 nm and d(020) = 0.137 nm. The lattice mismatch between TiNi3 and TiNi was calculated to be 2.5 %, with low strain energy. The order of effective formation enthalpies for TiNi3, TiNi and Ti2Ni phases formed between titanium and nickel was > > . The growth activation energy of TiNi3, TiNi and Ti2Ni phases was correspondingly 35.8 kJ/mol, 180.6 kJ/mol and 347.1 kJ/mol. When welding at 880 °C for 60 min, the highest shear strength of the joints could achieve 150 MPa. The joints fractured along the Ni/T2 interface, the fracture surface of joint was composed of elongated dimples and cellular pits, presenting a shear ductile fracture mode. FCC-Cu, FCC-Ni and (Ni, Cu)ss phases were detected on TC4 and T2 fracture surfaces by XRD. The interdiffusion coefficient ratio of (Ni in Cu)/(Cu in Ni) and (Ni in Ti)/(Ti in Ni) decreased gradually with increasing temperature.
{"title":"Bonding mechanism of TC4 titanium alloy/T2 copper vacuum diffusion bonded joint with nickel as transition interlayer","authors":"Baosheng Wu, Honggang Dong, Yueting Ma, Peng Li, Chao Li, Libing Huang","doi":"10.1016/j.jmapro.2024.09.099","DOIUrl":"10.1016/j.jmapro.2024.09.099","url":null,"abstract":"<div><div>Vacuum diffusion bonding of TC4 titanium alloy (TC4) to T2 copper (T2) using nickel foil as transition interlayer was explored. Ti<sub>3</sub>Ni, Ti<sub>2</sub>Ni, TiNi, AlNi<sub>2</sub>Ti and TiNi<sub>3</sub> phases arose at the TC4/Ni bonded interface, and Cu-Ni solid solution appeared in the Ni/T2 interface. Thereinto, AlNi<sub>2</sub>Ti was a kind of discontinuous nano precipitated phase, which distributed between TiNi and TiNi<sub>3</sub> phases. The crystallographic orientations of Ti<sub>2</sub>Ni, TiNi, AlNi<sub>2</sub>Ti and TiNi<sub>3</sub> phases were (201), (020), (<span><math><mn>1</mn><mover><mn>1</mn><mo>¯</mo></mover><mn>1</mn></math></span>) and (031), respectively. The interplanar spacing of (031), (<span><math><mn>1</mn><mover><mn>1</mn><mo>¯</mo></mover><mn>1</mn></math></span>) and (020) was correspondingly <em>d</em><sub>(031)</sub> = 0.144 nm, <span><math><msub><mi>d</mi><mfenced><mrow><mn>1</mn><mover><mn>1</mn><mo>¯</mo></mover><mn>1</mn></mrow></mfenced></msub></math></span> = 0.275 nm and <em>d</em><sub>(020)</sub> = 0.137 nm. The lattice mismatch between TiNi<sub>3</sub> and TiNi was calculated to be 2.5 %, with low strain energy. The order of effective formation enthalpies for TiNi<sub>3</sub>, TiNi and Ti<sub>2</sub>Ni phases formed between titanium and nickel was <span><math><mo>∆</mo><mi>H</mi><msub><mo>′</mo><mrow><mi>Ni</mi><msub><mi>Ti</mi><mn>2</mn></msub></mrow></msub></math></span> > <span><math><mo>∆</mo><mi>H</mi><msub><mo>′</mo><mtext>NiTi</mtext></msub></math></span> > <span><math><mo>∆</mo><mi>H</mi><msub><mo>′</mo><mrow><msub><mi>Ni</mi><mn>3</mn></msub><mi>Ti</mi></mrow></msub></math></span>. The growth activation energy of TiNi<sub>3</sub>, TiNi and Ti<sub>2</sub>Ni phases was correspondingly 35.8 kJ/mol, 180.6 kJ/mol and 347.1 kJ/mol. When welding at 880 °C for 60 min, the highest shear strength of the joints could achieve 150 MPa. The joints fractured along the Ni/T2 interface, the fracture surface of joint was composed of elongated dimples and cellular pits, presenting a shear ductile fracture mode. FCC-Cu, FCC-Ni and (Ni, Cu)<sub>ss</sub> phases were detected on TC4 and T2 fracture surfaces by XRD. The interdiffusion coefficient ratio of (Ni in Cu)/(Cu in Ni) and (Ni in Ti)/(Ti in Ni) decreased gradually with increasing temperature.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1309-1320"},"PeriodicalIF":6.1,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142424009","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 : 2024-10-03DOI: 10.1016/j.jmapro.2024.09.086
Refak Makeen , Kartikey Joshi , Mark H. Jhon , Patcharapit Promoppatum
A laser powder bed fusion (LPBF) process enables the production of intricate geometries for specialized applications demanding high precision in various industries such as medical, aerospace, and automotive. However, substantial thermal gradients in the LPBF process often led to residual stress, resulting in noticeable distortion and potential part failure of fabricated parts. Therefore, the present work investigates distortion prediction and geometry compensation for additively manufactured Ti-6Al-4V components employing a modified inherent strain method. Unlike previous studies, both relaxed distortions from substrate removal and as-built distortion are considered, incorporating specimens with varying geometrical features such as height and thickness. The study aims to comprehensively evaluate the efficacy of the modified inherent strain approach in capturing distortion under different build scenarios and assess the effectiveness of geometrical compensation in minimizing as-built distortion. Overall, we found that numerical models effectively capture relaxed deflection for samples with varied geometrical features, showing reasonable agreement with experimental results. Additionally, the as-built distortion of samples with thicknesses of 5 mm and above is well-predicted, with an average deviation between numerical and experimental results of approximately 0.125 mm. Nonetheless, we noted the challenge in capturing out-of-plane distortion for thin wedges, suggesting avenues for future investigation. Furthermore, geometry compensation reduces maximum distortion from 0.68 to 0.28 mm and average distortion from 0.15 to 0.05 mm. Multiple iterations of compensation yield insignificant differences in distortion reduction, which suggests sufficient distortion alleviation from single compensation for geometries explored in the present work. Overall, the study provides valuable insights into distortion prediction and compensation strategies for additively manufactured Ti-6Al-4V components.
{"title":"Distortion prediction and geometry compensation using modified inherent strain method for additively manufactured Ti-6Al-4V","authors":"Refak Makeen , Kartikey Joshi , Mark H. Jhon , Patcharapit Promoppatum","doi":"10.1016/j.jmapro.2024.09.086","DOIUrl":"10.1016/j.jmapro.2024.09.086","url":null,"abstract":"<div><div>A laser powder bed fusion (LPBF) process enables the production of intricate geometries for specialized applications demanding high precision in various industries such as medical, aerospace, and automotive. However, substantial thermal gradients in the LPBF process often led to residual stress, resulting in noticeable distortion and potential part failure of fabricated parts. Therefore, the present work investigates distortion prediction and geometry compensation for additively manufactured Ti-6Al-4V components employing a modified inherent strain method. Unlike previous studies, both relaxed distortions from substrate removal and as-built distortion are considered, incorporating specimens with varying geometrical features such as height and thickness. The study aims to comprehensively evaluate the efficacy of the modified inherent strain approach in capturing distortion under different build scenarios and assess the effectiveness of geometrical compensation in minimizing as-built distortion. Overall, we found that numerical models effectively capture relaxed deflection for samples with varied geometrical features, showing reasonable agreement with experimental results. Additionally, the as-built distortion of samples with thicknesses of 5 mm and above is well-predicted, with an average deviation between numerical and experimental results of approximately 0.125 mm. Nonetheless, we noted the challenge in capturing out-of-plane distortion for thin wedges, suggesting avenues for future investigation. Furthermore, geometry compensation reduces maximum distortion from 0.68 to 0.28 mm and average distortion from 0.15 to 0.05 mm. Multiple iterations of compensation yield insignificant differences in distortion reduction, which suggests sufficient distortion alleviation from single compensation for geometries explored in the present work. Overall, the study provides valuable insights into distortion prediction and compensation strategies for additively manufactured Ti-6Al-4V components.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1334-1347"},"PeriodicalIF":6.1,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423727","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 : 2024-10-03DOI: 10.1016/j.jmapro.2024.09.117
Gongbin Tang , Shulong Sun , Jinfeng Yang , Yiting Pan , Zhicheng Liu , Zhongwei Liang
The nickel-based superalloy Inconel X-750, valued for its exceptional mechanical properties, is used in gas-lubricated foil bearings. However, prolonged exposure to high temperatures can lead to wear failure, affecting their service life. Here, we propose a novel method named ultrasonic strengthening grinding (USG) that applies a WC coating on Inconel X-750. Friction tests reveal that at 600 °C, the friction coefficient and wear rate of the USG-treated samples were reduced by 30.2 % and 79.7 %, respectively. Detailed experiments and analysis demonstrate that the surface grain refinement and the WC-rich coating cooperate to improve the high-temperature tribological properties. These findings offer new insights into the design of wear-resistant coatings for enhancing the high-temperature tribological performance of Inconel X-750 Alloy.
{"title":"Fabrication and tribological properties of WC-reinforced Inconel X-750 alloy at elevated temperature","authors":"Gongbin Tang , Shulong Sun , Jinfeng Yang , Yiting Pan , Zhicheng Liu , Zhongwei Liang","doi":"10.1016/j.jmapro.2024.09.117","DOIUrl":"10.1016/j.jmapro.2024.09.117","url":null,"abstract":"<div><div>The nickel-based superalloy Inconel X-750, valued for its exceptional mechanical properties, is used in gas-lubricated foil bearings. However, prolonged exposure to high temperatures can lead to wear failure, affecting their service life. Here, we propose a novel method named ultrasonic strengthening grinding (USG) that applies a WC coating on Inconel X-750. Friction tests reveal that at 600 °C, the friction coefficient and wear rate of the USG-treated samples were reduced by 30.2 % and 79.7 %, respectively. Detailed experiments and analysis demonstrate that the surface grain refinement and the WC-rich coating cooperate to improve the high-temperature tribological properties. These findings offer new insights into the design of wear-resistant coatings for enhancing the high-temperature tribological performance of Inconel X-750 Alloy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1321-1333"},"PeriodicalIF":6.1,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423726","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 : 2024-10-03DOI: 10.1016/j.jmapro.2024.09.089
Shujun Chen, Tianming Li, Fan Jiang, Goukai Zhang, Shitong Fang
In response to the inconsistency between the features obtained by deep learning models and the quality features reflected by the physical laws of the welding process, this study proposes a solution by integrating a physical prior information model with a CNN model. Initially, the physical laws of the welding process are utilized to annotate the arc, weld pool, and weld seam features relevant to quality, which are then acquired through image processing algorithms, thereby converting the physical laws into a prior information model. Subsequently, this prior information model guides the CNN model for quality recognition, and the CNN model's attention to features is explained through visualization methods to elucidate the relationship between features and quality recognition. Experimental results demonstrate that under the guidance of the prior information model, the CNN model not only automatically focuses on features relevant to quality but also achieves a differential feature attention strategy, thereby improving the recognition accuracy of different outcomes. This research provides a new perspective for deep learning in the field of welding quality recognition.
{"title":"Enhancing VPPA welding quality prediction: A hybrid model integrating prior physical knowledge and CNN analysis","authors":"Shujun Chen, Tianming Li, Fan Jiang, Goukai Zhang, Shitong Fang","doi":"10.1016/j.jmapro.2024.09.089","DOIUrl":"10.1016/j.jmapro.2024.09.089","url":null,"abstract":"<div><div>In response to the inconsistency between the features obtained by deep learning models and the quality features reflected by the physical laws of the welding process, this study proposes a solution by integrating a physical prior information model with a CNN model. Initially, the physical laws of the welding process are utilized to annotate the arc, weld pool, and weld seam features relevant to quality, which are then acquired through image processing algorithms, thereby converting the physical laws into a prior information model. Subsequently, this prior information model guides the CNN model for quality recognition, and the CNN model's attention to features is explained through visualization methods to elucidate the relationship between features and quality recognition. Experimental results demonstrate that under the guidance of the prior information model, the CNN model not only automatically focuses on features relevant to quality but also achieves a differential feature attention strategy, thereby improving the recognition accuracy of different outcomes. This research provides a new perspective for deep learning in the field of welding quality recognition.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1282-1295"},"PeriodicalIF":6.1,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423661","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 : 2024-10-03DOI: 10.1016/j.jmapro.2024.09.114
Wei Cheng , Xiu-Bo Liu , Fei-Zhi Zhang , Xin-Gong Li , Ji-Xiang Liang , Xiang-Yu Liu , Jun Zheng , Jin-Peng Zhu
During manufacturing processes, alloys face increasingly demanding requirements for their mechanical and tribological properties, underscoring the importance of revealing their deformation mechanisms. This study employed molecular dynamics simulation to construct models of FeCrNi (C1), FeCoCrNi (C2), FeCrNiCu (C3), and FeCoCrNiCu (C4), investigating the tribological properties of C1 alloy under various conditions and the mechanical properties across a wide temperature range (223–1073 K). The results indicate that the elastic modulus of the alloys follows the order C2 > C4 > C3 > C1 across the temperature range of 223 K to 1073 K. The elastic modulus increases with rising temperatures and decreases before rising once again as temperatures decrease. The phase transitions become more pronounced below 300 K. The addition of Co elements to the FeCrNi alloy contributes to fine-grain strengthening, uniform distribution of internal stress and strain, reduction in local stress concentration, and improvement of the alloy ductility and tensile strength. Compared to sliding friction, rolling friction reduces the number of worn atoms; however, the tensile and shear effects cause an increase in the stress gradient, leading to more severe subsurface damage and shear deformation. Temperature significantly affects the tribological properties of the alloys: phase transitions at high temperatures promote dislocation slip and plastic deformation, while at low temperatures, higher hardness and strength are observed. The roughness of stacking faults is greatly influenced by temperature, with an increase at the low-temperature range (223–273 K), a decrease in the mid-temperature range (273–673 K), and a smoother surface at the high-temperature range (673–1073 K). The research aims to provide a deeper understanding of the excellent mechanical and tribological properties of FeCrNi alloy at the micro/nano scales, thereby advancing their application and development in manufacturing processes.
在制造过程中，合金的机械和摩擦学性能面临着越来越苛刻的要求，因此揭示其变形机理显得尤为重要。本研究采用分子动力学模拟构建了铁铬镍（C1）、铁钴铬镍（C2）、铁铬镍铜（C3）和铁钴铬镍铜（C4）的模型，研究了 C1 合金在各种条件下的摩擦学性能以及在较宽温度范围（223-1073 K）内的力学性能。结果表明，在 223 K 至 1073 K 的温度范围内，合金的弹性模量遵循 C2 > C4 > C3 > C1 的顺序。在铁铬镍合金中添加 Co 元素有助于细晶粒强化、均匀分布内部应力和应变、减少局部应力集中以及提高合金的延展性和抗拉强度。与滑动摩擦相比，滚动摩擦减少了磨损原子的数量；然而，拉伸和剪切效应会导致应力梯度增加，从而导致更严重的表面下损伤和剪切变形。温度对合金的摩擦学特性有很大影响：高温下的相变会促进位错滑移和塑性变形，而在低温下则会产生更高的硬度和强度。堆叠断层的粗糙度受温度影响很大，在低温范围（223-273 K）会增加，在中温范围（273-673 K）会减少，而在高温范围（673-1073 K）表面会更光滑。该研究旨在深入了解铁铬镍合金在微米/纳米尺度上的优异机械和摩擦学特性，从而推动其在制造工艺中的应用和发展。
{"title":"Mechanical properties, nano-tribological behavior and deformation mechanism of FeCrNi MEA with the addition of Co/Cu: Molecular dynamics simulation","authors":"Wei Cheng , Xiu-Bo Liu , Fei-Zhi Zhang , Xin-Gong Li , Ji-Xiang Liang , Xiang-Yu Liu , Jun Zheng , Jin-Peng Zhu","doi":"10.1016/j.jmapro.2024.09.114","DOIUrl":"10.1016/j.jmapro.2024.09.114","url":null,"abstract":"<div><div>During manufacturing processes, alloys face increasingly demanding requirements for their mechanical and tribological properties, underscoring the importance of revealing their deformation mechanisms. This study employed molecular dynamics simulation to construct models of FeCrNi (C1), FeCoCrNi (C2), FeCrNiCu (C3), and FeCoCrNiCu (C4), investigating the tribological properties of C1 alloy under various conditions and the mechanical properties across a wide temperature range (223–1073 K). The results indicate that the elastic modulus of the alloys follows the order C2 > C4 > C3 > C1 across the temperature range of 223 K to 1073 K. The elastic modulus increases with rising temperatures and decreases before rising once again as temperatures decrease. The phase transitions become more pronounced below 300 K. The addition of Co elements to the FeCrNi alloy contributes to fine-grain strengthening, uniform distribution of internal stress and strain, reduction in local stress concentration, and improvement of the alloy ductility and tensile strength. Compared to sliding friction, rolling friction reduces the number of worn atoms; however, the tensile and shear effects cause an increase in the stress gradient, leading to more severe subsurface damage and shear deformation. Temperature significantly affects the tribological properties of the alloys: phase transitions at high temperatures promote dislocation slip and plastic deformation, while at low temperatures, higher hardness and strength are observed. The roughness of stacking faults is greatly influenced by temperature, with an increase at the low-temperature range (223–273 K), a decrease in the mid-temperature range (273–673 K), and a smoother surface at the high-temperature range (673–1073 K). The research aims to provide a deeper understanding of the excellent mechanical and tribological properties of FeCrNi alloy at the micro/nano scales, thereby advancing their application and development in manufacturing processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1348-1359"},"PeriodicalIF":6.1,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423728","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 : 2024-10-03DOI: 10.1016/j.jmapro.2024.09.120
Emine Şirin , Çağrı Vakkas Yıldırım , Şenol Şirin , Turgay Kıvak , Murat Sarıkaya
Despite being expensive and difficult to process, the Ti6Al4V alloy is a vital component for crucial industries. To improve its machinability and accomplish sustainable production, environmentally friendly cooling and lubricating agencies are used. Studies on the machinability of the alloy are still necessary because of its unique features and significance in vital industries like aerospace, defense, and medicine. Therefore, this investigation focuses on tool wear, temperature, and surface integrity for sustainable milling Ti6Al4V under various machining environments, i.e., dry, pure-MQL, LN2, hBN, CuO-doped nanofluids, and hybrid methods. The produced nanofluids' thermophysical and rheological characteristics were examined in the study's initial phase. Because of the results from the first stage, machining performance indicators were assessed in the subsequent milling experiments. As a result, CuO-doped nanofluids gave improved results in terms of viscosity and pH. The best results obtained in the LN2 + CuO hybrid cooling lubrication environment in important machinability outcomes such as tool wear and surface integrity were attributed to the rheological properties of CuO-doped nanofluid and its harmonious cooperation with LN2-cryogenic cooling.
{"title":"Comprehensive analysis of cutting temperature, tool wear, surface integrity and tribological properties in sustainable milling of Ti6Al4V alloy: LN2, nanofluid and hybrid machining","authors":"Emine Şirin , Çağrı Vakkas Yıldırım , Şenol Şirin , Turgay Kıvak , Murat Sarıkaya","doi":"10.1016/j.jmapro.2024.09.120","DOIUrl":"10.1016/j.jmapro.2024.09.120","url":null,"abstract":"<div><div>Despite being expensive and difficult to process, the Ti6Al4V alloy is a vital component for crucial industries. To improve its machinability and accomplish sustainable production, environmentally friendly cooling and lubricating agencies are used. Studies on the machinability of the alloy are still necessary because of its unique features and significance in vital industries like aerospace, defense, and medicine. Therefore, this investigation focuses on tool wear, temperature, and surface integrity for sustainable milling Ti6Al4V under various machining environments, i.e., dry, pure-MQL, LN<sub>2</sub>, hBN, CuO-doped nanofluids, and hybrid methods. The produced nanofluids' thermophysical and rheological characteristics were examined in the study's initial phase. Because of the results from the first stage, machining performance indicators were assessed in the subsequent milling experiments. As a result, CuO-doped nanofluids gave improved results in terms of viscosity and pH. The best results obtained in the LN<sub>2</sub> + CuO hybrid cooling lubrication environment in important machinability outcomes such as tool wear and surface integrity were attributed to the rheological properties of CuO-doped nanofluid and its harmonious cooperation with LN<sub>2</sub>-cryogenic cooling.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1360-1371"},"PeriodicalIF":6.1,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423729","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}
Pub Date : 2024-10-03DOI: 10.1016/j.jmapro.2024.09.098
John D. Kechagias , Stephanos P. Zaoutsos
Material extrusion is increasingly used to make functional parts in small batches that are challenging to produce with traditional machining. Also, intensive efforts are being made to develop new eco–friendly materials. This work investigates the strength of multilayer samples made in sandwich form with 4–5–4 layers of 0.3 mm layer thickness, externally with polylacticacid wood (PLA/wood, 61.5 % of specimens' material) and internally with pure PLA (38.5 % of specimens' material), under tensile loads. The intent is to investigate the possibility of manufacturing biocompatible components that take advantage of the excellent surface properties of wood externally and the durability properties of PLA internally. For this purpose, a designed experiment following the Taguchi L9 orthogonal array was prepared, and nine samples were fabricated: three with pure PLA, three with a sandwich PLA/wood–PLA–PLA/wood form, and three with composite PLA/wood form. Printing speed and temperature were varied during the experiment, and the results were examined using the analysis of means and residuals. Sandwich specimens improve tensile strength and elastic modulus by 100 % and 50 % compared to PLA/wood components while exhibiting slightly better surface roughness parameters, i.e., Ra and Rz, about ∼10 % lower values. Additionally, even if PLA parts showed better strength and surface texture than sandwich parts (∼100 % and ∼56 % higher tensile strength and elastic modulus), they had lower performance in terms of PLA–PLA/wood material ratio, i.e., 160 % more PLA than sandwich parts. The findings of this research, with the potential to design functional and sustainable new products with optimal performance, are significant and can be exploited in various industries.
{"title":"An assessment of PLA/wood with PLA core sandwich multilayer component tensile strength under different 3D printing conditions","authors":"John D. Kechagias , Stephanos P. Zaoutsos","doi":"10.1016/j.jmapro.2024.09.098","DOIUrl":"10.1016/j.jmapro.2024.09.098","url":null,"abstract":"<div><div>Material extrusion is increasingly used to make functional parts in small batches that are challenging to produce with traditional machining. Also, intensive efforts are being made to develop new eco–friendly materials. This work investigates the strength of multilayer samples made in sandwich form with 4–5–4 layers of 0.3 mm layer thickness, externally with polylacticacid wood (PLA/wood, 61.5 % of specimens' material) and internally with pure PLA (38.5 % of specimens' material), under tensile loads. The intent is to investigate the possibility of manufacturing biocompatible components that take advantage of the excellent surface properties of wood externally and the durability properties of PLA internally. For this purpose, a designed experiment following the Taguchi L<sub>9</sub> orthogonal array was prepared, and nine samples were fabricated: three with pure PLA, three with a sandwich PLA/wood–PLA–PLA/wood form, and three with composite PLA/wood form. Printing speed and temperature were varied during the experiment, and the results were examined using the analysis of means and residuals. Sandwich specimens improve tensile strength and elastic modulus by 100 % and 50 % compared to PLA/wood components while exhibiting slightly better surface roughness parameters, i.e., Ra and Rz, about ∼10 % lower values. Additionally, even if PLA parts showed better strength and surface texture than sandwich parts (∼100 % and ∼56 % higher tensile strength and elastic modulus), they had lower performance in terms of PLA–PLA/wood material ratio, i.e., 160 % more PLA than sandwich parts. The findings of this research, with the potential to design functional and sustainable new products with optimal performance, are significant and can be exploited in various industries.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1240-1249"},"PeriodicalIF":6.1,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423659","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 : 2024-10-03DOI: 10.1016/j.jmapro.2024.09.113
Bao Qu , Chunzhang Zhao , Kehuan Wang , Jie Zhao , Shanshan Cui , Bin Gao , Gang Liu
The simultaneous achievement of high strength and precision in the fabrication of titanium alloy thin-walled components is a long-standing issue. This work proposes a novel integrated forming process, named Hot Forming with In-situ Stress Relaxation-Aging (short for HF-ISRA) to solve the special issue. In contrast to usual isothermal forming, the forming temperature in the proposed process is raised to the solution treatment temperature. Dies at a lower temperature realize in-situ stress relaxation-aging after hot forming. The role of the dies, in addition to forming, is also achieved post-forming heat treatment. This novel process comprises three main steps: solution heat treatment, rapid forming at solution temperature, and in-situ stress relaxation-aging. An experimental prototype of HF-ISRA was developed for V-bending test, in which a sheet blank was rapidly heated using electric current and the forming die was heated using heating rods. The process window of the proposed HF-ISRA was established based on the V-bending and uniaxial tensile tests of the TA15 titanium alloy. The results showed that compared with cold forming, the springback angle obtained using the optimized HF-ISRA decreased by 97.8 %, from 9°06′ to only 12′. The tensile strength at room temperature and 500 °C was improved by 4.4 % and 10.9 % compared with the as-received material, respectively. The relaxation mechanisms of αs were the precipitation, growth, and then globularization. The relaxation mechanism of αp was dislocation movements. The strength improvement in HF-ISRA was due to the formation of αs and dislocations strengthening. The stress-induced twinning in αs was also a contributor. The proposed novel process provides a new route for the fabrication of titanium alloy thin-walled components with high precision and strength.
在制造钛合金薄壁部件时，如何同时实现高强度和高精度是一个长期存在的问题。为解决这一特殊问题，本研究提出了一种新型集成成形工艺，命名为 "原位应力松弛-时效热成形"（简称 HF-ISRA）。与通常的等温成形不同，该工艺中的成形温度提高到了固溶处理温度。温度较低的模具可在热成形后实现原位应力松弛时效。模具的作用除了成型外，还实现了成型后的热处理。这种新型工艺包括三个主要步骤：固溶热处理、在固溶温度下快速成型和原位应力松弛时效。开发了用于 V 形弯曲试验的 HF-ISRA 实验原型，其中使用电流快速加热板材坯料，并使用加热棒加热成型模具。根据 TA15 钛合金的 V 形弯曲和单轴拉伸试验，确定了拟议 HF-ISRA 的工艺窗口。结果表明，与冷成形相比，使用优化的 HF-ISRA 所获得的回弹角降低了 97.8%，从 9°06′ 降至仅 12′。室温和 500 °C 下的拉伸强度分别比初始材料提高了 4.4% 和 10.9%。αs的弛豫机制为沉淀、生长和球化。αp 的弛豫机制是位错运动。HF-ISRA 的强度提高是由于 αs 的形成和位错的强化。应力引起的αs孪晶也是一个原因。所提出的新工艺为制造具有高精度和高强度的钛合金薄壁部件提供了一条新途径。
{"title":"A novel integrated hot forming with in-situ stress relaxation-aging for titanium alloy thin-walled components","authors":"Bao Qu , Chunzhang Zhao , Kehuan Wang , Jie Zhao , Shanshan Cui , Bin Gao , Gang Liu","doi":"10.1016/j.jmapro.2024.09.113","DOIUrl":"10.1016/j.jmapro.2024.09.113","url":null,"abstract":"<div><div>The simultaneous achievement of high strength and precision in the fabrication of titanium alloy thin-walled components is a long-standing issue. This work proposes a novel integrated forming process, named Hot Forming with In-situ Stress Relaxation-Aging (short for HF-ISRA) to solve the special issue. In contrast to usual isothermal forming, the forming temperature in the proposed process is raised to the solution treatment temperature. Dies at a lower temperature realize in-situ stress relaxation-aging after hot forming. The role of the dies, in addition to forming, is also achieved post-forming heat treatment. This novel process comprises three main steps: solution heat treatment, rapid forming at solution temperature, and in-situ stress relaxation-aging. An experimental prototype of HF-ISRA was developed for V-bending test, in which a sheet blank was rapidly heated using electric current and the forming die was heated using heating rods. The process window of the proposed HF-ISRA was established based on the V-bending and uniaxial tensile tests of the TA15 titanium alloy. The results showed that compared with cold forming, the springback angle obtained using the optimized HF-ISRA decreased by 97.8 %, from 9°06′ to only 12′. The tensile strength at room temperature and 500 °C was improved by 4.4 % and 10.9 % compared with the as-received material, respectively. The relaxation mechanisms of α<sub>s</sub> were the precipitation, growth, and then globularization. The relaxation mechanism of α<sub>p</sub> was dislocation movements. The strength improvement in HF-ISRA was due to the formation of α<sub>s</sub> and dislocations strengthening. The stress-induced twinning in α<sub>s</sub> was also a contributor. The proposed novel process provides a new route for the fabrication of titanium alloy thin-walled components with high precision and strength.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1296-1308"},"PeriodicalIF":6.1,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423725","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}
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