Journal of Manufacturing Processes最新文献_第9页

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.

{"title":"Analytical model for corrugated rolling of composite plates considering the shear effect","authors":"Yuanming Liu , Jun Su , Dongping He , Pingju Hao , Yanxiao Liu , Zhenhua Wang , Tao Wang","doi":"10.1016/j.jmapro.2025.01.025","DOIUrl":"10.1016/j.jmapro.2025.01.025","url":null,"abstract":"<div><div>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.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 1069-1081"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132044","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

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

A robotic surface inspection framework and machine-learning based optimal segmentation for aerospace and precision manufacturing

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.2024.12.019

Arun Nandagopal, Jonas Beachy, Colin Acton, Xu Chen

Quality control is key in the advanced manufacturing of complex parts. Modern precision manufacturing must identify and exclude parts with visual imperfections (e.g., scratches, discolorations, dents, tool marks, etc.) to ensure compliant operation. This inspection process – often manual – is not only time-consuming but also burdensome, subjective, and requires months to years of training, particularly for high-volume production operations. A reliable robotic visual inspection solution, however, has been hindered by the small defect size, intricate part characteristics, and demand for high inspection accuracy. This paper proposes a novel automated inspection path planning framework that addresses these core hurdles through four innovations: camera-parameter-based mesh segmentation, ray-tracing viewpoint placement, robot-agnostic viewpoint planning, and Bayesian optimization for faster segmentation. The effectiveness of the proposed workflow is tested with simulation and experimentation on a robotic inspection of heterogeneous complex geometries.

{"title":"A robotic surface inspection framework and machine-learning based optimal segmentation for aerospace and precision manufacturing","authors":"Arun Nandagopal, Jonas Beachy, Colin Acton, Xu Chen","doi":"10.1016/j.jmapro.2024.12.019","DOIUrl":"10.1016/j.jmapro.2024.12.019","url":null,"abstract":"<div><div>Quality control is key in the advanced manufacturing of complex parts. Modern precision manufacturing must identify and exclude parts with visual imperfections (e.g., scratches, discolorations, dents, tool marks, etc.) to ensure compliant operation. This inspection process – often manual – is not only time-consuming but also burdensome, subjective, and requires months to years of training, particularly for high-volume production operations. A reliable robotic visual inspection solution, however, has been hindered by the small defect size, intricate part characteristics, and demand for high inspection accuracy. This paper proposes a novel automated inspection path planning framework that addresses these core hurdles through four innovations: camera-parameter-based mesh segmentation, ray-tracing viewpoint placement, robot-agnostic viewpoint planning, and Bayesian optimization for faster segmentation. The effectiveness of the proposed workflow is tested with simulation and experimentation on a robotic inspection of heterogeneous complex geometries.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"134 ","pages":"Pages 146-157"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143132266","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

Evolution of macro/mesoscopic thermal-mechanical fields in friction lap joining of surface-textured Al alloy to CFRTP

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.2025.01.085

Suyu Wang , Yuxin Xu , Wenquan Wang , Xinge Zhang , Yuhua Chen , Peihao Geng , Ninshu Ma

Controlling interfacial thermal-mechanical condition is key to achieving high-performance joining between carbon fiber reinforced thermoplastic (CFRTP) and metal, especially in friction lap joining (FLJ) processes that enhance mechanical interlocking through preformed micro-textured metal surfaces. In the current work, a novel sequential numerical simulation strategy using Eulerian-based finite element (FE) modeling was developed. This approach aims to deeply investigate the macroscopic thermal-mechanical field evolution and the mesoscopic material flow-filling within localized laser-ablated grooves in FLJ of surface textured Al alloy/carbon fiber reinforced polyamide-66 (PA66). The significance of thermal-mechanical fields in influencing the joint quality was highlighted by quantifying experimentally validated data including peak temperature, high-temperature dwelling time, interface melting depth and deformation depth. As the evaluation index of the interfacial reaction degree, the average reaction time between molten PA66 and metallic surface at each position of the grooves in the whole joining zone was calculated through the obtained simulation results and numeral-form combination strategy. The recommended ranges for peak temperature, average reaction time, and CFRTP thinning ratio to achieve high-performance joints were identified as 320 °C–360 °C, 3.5 s–4.5 s, and <6.5 %, providing new insight and quantitative standard for the performance evaluation of hybrid material joining.

{"title":"Evolution of macro/mesoscopic thermal-mechanical fields in friction lap joining of surface-textured Al alloy to CFRTP","authors":"Suyu Wang , Yuxin Xu , Wenquan Wang , Xinge Zhang , Yuhua Chen , Peihao Geng , Ninshu Ma","doi":"10.1016/j.jmapro.2025.01.085","DOIUrl":"10.1016/j.jmapro.2025.01.085","url":null,"abstract":"<div><div>Controlling interfacial thermal-mechanical condition is key to achieving high-performance joining between carbon fiber reinforced thermoplastic (CFRTP) and metal, especially in friction lap joining (FLJ) processes that enhance mechanical interlocking through preformed micro-textured metal surfaces. In the current work, a novel sequential numerical simulation strategy using Eulerian-based finite element (FE) modeling was developed. This approach aims to deeply investigate the macroscopic thermal-mechanical field evolution and the mesoscopic material flow-filling within localized laser-ablated grooves in FLJ of surface textured Al alloy/carbon fiber reinforced polyamide-66 (PA66). The significance of thermal-mechanical fields in influencing the joint quality was highlighted by quantifying experimentally validated data including peak temperature, high-temperature dwelling time, interface melting depth and deformation depth. As the evaluation index of the interfacial reaction degree, the average reaction time between molten PA66 and metallic surface at each position of the grooves in the whole joining zone was calculated through the obtained simulation results and numeral-form combination strategy. The recommended ranges for peak temperature, average reaction time, and CFRTP thinning ratio to achieve high-performance joints were identified as 320 °C–360 °C, 3.5 s–4.5 s, and <6.5 %, providing new insight and quantitative standard for the performance evaluation of hybrid material joining.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"136 ","pages":"Pages 356-369"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143339278","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

Surface tension confined digital light processing for hydrogel printing with high availability

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.2025.01.086

Feng Xu , Hang Jin , Zhuomin Zhou , Acan Jiang , Lingling Liu , Haohang Fang , Qiang Gao , Yu-Chuan Su , Zhengmao Ding , Qinnan Chen , Songyue Chen , Daoheng Sun

Digital light processing (DLP) has emerged as one of the most promising methods for constructing intricate 3D hydrogel structures. However, the material availability of hydrogels is quite limited for resin vat-based printing. To overcome this issue, we propose a surface tension confined digital light processing (STC-DLP) technique that utilizes liquid surface tension and surface-treated substrates to confine the hydrogel solution during printing, to minimize the solution consumption. The “top-down” DLP printing enables layer-by-layer curing of hydrogel solutions into controlled 3D structures. A soft and a rigid hydrogel solution was selected as demonstration. By adding hydrogel solution with desired volume, highly accurate microtissue models, flexible sensors, and microfluidic chips with complex 3D structures were fabricated with high solution availability. This approach achieves efficient utilization of hydrogel solutions, and is expected to be especially applicable for printing of scarce or expensive materials.

{"title":"Surface tension confined digital light processing for hydrogel printing with high availability","authors":"Feng Xu , Hang Jin , Zhuomin Zhou , Acan Jiang , Lingling Liu , Haohang Fang , Qiang Gao , Yu-Chuan Su , Zhengmao Ding , Qinnan Chen , Songyue Chen , Daoheng Sun","doi":"10.1016/j.jmapro.2025.01.086","DOIUrl":"10.1016/j.jmapro.2025.01.086","url":null,"abstract":"<div><div>Digital light processing (DLP) has emerged as one of the most promising methods for constructing intricate 3D hydrogel structures. However, the material availability of hydrogels is quite limited for resin vat-based printing. To overcome this issue, we propose a surface tension confined digital light processing (STC-DLP) technique that utilizes liquid surface tension and surface-treated substrates to confine the hydrogel solution during printing, to minimize the solution consumption. The “top-down” DLP printing enables layer-by-layer curing of hydrogel solutions into controlled 3D structures. A soft and a rigid hydrogel solution was selected as demonstration. By adding hydrogel solution with desired volume, highly accurate microtissue models, flexible sensors, and microfluidic chips with complex 3D structures were fabricated with high solution availability. This approach achieves efficient utilization of hydrogel solutions, and is expected to be especially applicable for printing of scarce or expensive materials.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"136 ","pages":"Pages 370-379"},"PeriodicalIF":6.1,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143339279","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

Shallow-angled jet impingement generated channel geometry prediction in milling 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.2024.12.047

Deepu Kumar T.N., Srinivasu D.S.

To manufacture complex parts using abrasive waterjets (AWJs) in milling mode, one should ensure that the local features of the target part geometry match with the channel shape produced by manipulating the operating parameters, such as jet impingement angle (α) and traverse speed (V_f). Hence, generating surfaces with tight tolerances demands control over the channel cross-section profile (CP) and its characteristics (maximum erosion depth, top width, cross-section area, and trailing edge angle). Despite AWJ technology's existence for decades, there have been limited attempts to obtain control over channel geometries. Since AWJ is a complex three-phase mixture (air-water-particles), determining the particle flow properties in AWJ for material removal is of utmost importance. These circumstances seek to establish a modelling approach for predicting the channel geometry under the change in α and V_f. This paper proposes an innovative model for predicting CPs obtained at shallow-angle jet (SAJ) impinged erosion trials, incorporating the insights gained on channel formation mathematically. The Ti-6Al-4V alloy is highly challenging to mill by conventional methods used for experiments. The modelling results demonstrate that by considering the mathematical relationship between the specific cutting energy associated with α and V_f and corresponding jet flow properties in the model, the prediction capability improved by 98 %. Overall, within the range of α (50⁰–90⁰) and V_f (3000–5000 mm/min), the model's prediction error of channel characteristics is <10 %, and the mean absolute error in channel shape is 22.74 μm. Strong conformity is observed with a correlation coefficient of 0.98 between modelled and experimental profiles.

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引用次数: 0