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}
Pub Date : 2026-01-21DOI: 10.1016/j.jmapro.2026.01.047
Pengfei Zhang , Hanxiao Zhao , Ang Li , Chao Sun , Hongzhe Zhang , Naohiko Sugita , Liming Shu
Tool wear and remaining useful life (RUL) prediction are critical for ensuring machining quality and reducing production costs, playing an important role in deep-hole machining. Recently, physics-informed neural network (PINN) has attracted great attention to achieve this goal. However, the weights between physics-based models and data-driven models are often set empirically, which severely affects training accuracy and stability. To address this issue, this paper proposes a PINN with adaptive loss weighting, by quantifying the variance of prediction errors for tool wear and RUL prediction. First, multi-channel signals in deep hole boring are used to extract time-domain and frequency-domain features. Then, correlation coefficients between tool wear and features are calculated for feature selection, and combined with cutting stroke information to form the dataset. Next, based on the cutting stroke and flank wear values, a tool wear rate model is constructed using the least squares method. This equation serves as the physical consistency constraint of the PINN. The total loss function is constructed by combining the data loss from the data-driven model, the monotonicity loss, and the physical consistency loss. Finally, based on the AutoRegressive Integrated Moving Average (ARIMA) model and historical tool wear values, multi-step-ahead forecasting of tool wear and RUL prediction are achieved. Results show that the proposed PINN with adaptive loss weighting achieves the best tool wear prediction performance, compared with PINNs without weight adjustment (fixed weights), without monotonicity constraints, or without physical consistency constraints. Moreover, ARIMA multi-step-ahead forecasts closely match the measured tool wear and outperform the GRU baseline. The findings of this paper lay the foundation for automation and even unmanned operation in deep-hole machining.
{"title":"A physics-informed neural network with adaptive loss weighting for tool wear and remaining useful life prediction in deep hole boring","authors":"Pengfei Zhang , Hanxiao Zhao , Ang Li , Chao Sun , Hongzhe Zhang , Naohiko Sugita , Liming Shu","doi":"10.1016/j.jmapro.2026.01.047","DOIUrl":"10.1016/j.jmapro.2026.01.047","url":null,"abstract":"<div><div>Tool wear and remaining useful life (RUL) prediction are critical for ensuring machining quality and reducing production costs, playing an important role in deep-hole machining. Recently, physics-informed neural network (PINN) has attracted great attention to achieve this goal. However, the weights between physics-based models and data-driven models are often set empirically, which severely affects training accuracy and stability. To address this issue, this paper proposes a PINN with adaptive loss weighting, by quantifying the variance of prediction errors for tool wear and RUL prediction. First, multi-channel signals in deep hole boring are used to extract time-domain and frequency-domain features. Then, correlation coefficients between tool wear and features are calculated for feature selection, and combined with cutting stroke information to form the dataset. Next, based on the cutting stroke and flank wear values, a tool wear rate model is constructed using the least squares method. This equation serves as the physical consistency constraint of the PINN. The total loss function is constructed by combining the data loss from the data-driven model, the monotonicity loss, and the physical consistency loss. Finally, based on the AutoRegressive Integrated Moving Average (ARIMA) model and historical tool wear values, multi-step-ahead forecasting of tool wear and RUL prediction are achieved. Results show that the proposed PINN with adaptive loss weighting achieves the best tool wear prediction performance, compared with PINNs without weight adjustment (fixed weights), without monotonicity constraints, or without physical consistency constraints. Moreover, ARIMA multi-step-ahead forecasts closely match the measured tool wear and outperform the GRU baseline. The findings of this paper lay the foundation for automation and even unmanned operation in deep-hole machining.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 82-98"},"PeriodicalIF":6.8,"publicationDate":"2026-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036890","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 study investigates the impact of flank face coolant nozzle orientation on tool wear suppression in the high-speed milling of Inconel 718. Preliminary dry milling of Ti-6Al-4V with a Tool-Nose-Aimed (TNA) tool revealed severe flank wear at the bolt side edge. This failure mode persisted in Inconel 718, where the TNA tool suffered from severe adhesion and brittle fracture at this location under dry, flood and all high-pressure coolant (HPC) conditions except ultra-high pressure coolant (UHPC) at 20 MPa. Thermal and Computational Fluid Dynamics (CFD) simulations diagnosed the cause: the bolt side edge is a thermal throttling zone, and the TNA's coolant jet core deviates from this critical spot. Guided by this analysis, a novel Bolt-Side-Edge-Flank-Aimed (BSEFA) tool was designed. Its nozzle orientation was optimized to ensure the jet core directly impinges on the flank face of the bolt side edge, enhancing convective heat transfer through higher liquidity, velocity, and Turbulence Kinetic Energy (TKE). Experimentally, the BSEFA tool suppressed catastrophic failure, massive adhesion and reduced maximum flank wear (VBmax) within the wear land by 40–56% compared to the TNA tool. CFD results confirmed the mechanism, showing the optimized nozzle delivered superior coolant coverage (liquidity >0.95), higher velocity (>110 m/s), and drastically intensified turbulence (TKE increase >150%) at the target. This work establishes that strategic coolant orientation surpasses indiscriminate pressure increase. The BSEFA strategy enables high performance with minimal flow rate (<1.0 L/min), representing a > 95% reduction versus flood cooling, offering a highly efficient and sustainable machining strategy.
{"title":"Reducing tool wear in high-speed milling of Inconel 718 by optimizing flank-face coolant direction: A CFD-supported approach toward sustainable machining","authors":"Jingtian Mao , Kensuke Tsuchiya , Chikara Morigo , Shinji Yukinari , Hiroki Tahara , Yoshihide Kurashiki","doi":"10.1016/j.jmapro.2026.01.065","DOIUrl":"10.1016/j.jmapro.2026.01.065","url":null,"abstract":"<div><div>This study investigates the impact of flank face coolant nozzle orientation on tool wear suppression in the high-speed milling of Inconel 718. Preliminary dry milling of Ti-6Al-4V with a Tool-Nose-Aimed (TNA) tool revealed severe flank wear at the bolt side edge. This failure mode persisted in Inconel 718, where the TNA tool suffered from severe adhesion and brittle fracture at this location under dry, flood and all high-pressure coolant (HPC) conditions except ultra-high pressure coolant (UHPC) at 20 MPa. Thermal and Computational Fluid Dynamics (CFD) simulations diagnosed the cause: the bolt side edge is a thermal throttling zone, and the TNA's coolant jet core deviates from this critical spot. Guided by this analysis, a novel Bolt-Side-Edge-Flank-Aimed (BSEFA) tool was designed. Its nozzle orientation was optimized to ensure the jet core directly impinges on the flank face of the bolt side edge, enhancing convective heat transfer through higher liquidity, velocity, and Turbulence Kinetic Energy (TKE). Experimentally, the BSEFA tool suppressed catastrophic failure, massive adhesion and reduced maximum flank wear (VB<sub>max</sub>) within the wear land by 40–56% compared to the TNA tool. CFD results confirmed the mechanism, showing the optimized nozzle delivered superior coolant coverage (liquidity >0.95), higher velocity (>110 m/s), and drastically intensified turbulence (TKE increase >150%) at the target. This work establishes that strategic coolant orientation surpasses indiscriminate pressure increase. The BSEFA strategy enables high performance with minimal flow rate (<1.0 L/min), representing a > 95% reduction versus flood cooling, offering a highly efficient and sustainable machining strategy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 111-133"},"PeriodicalIF":6.8,"publicationDate":"2026-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036892","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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