首页 > 最新文献

Journal of Manufacturing Processes最新文献

英文 中文
Effect of minimum quality lubrication on micromilling of TiBw/TA15 composites considering tool wear 考虑刀具磨损的最低质量润滑对TiBw/TA15复合材料微铣削的影响
IF 6.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-02-15 Epub Date: 2026-01-17 DOI: 10.1016/j.jmapro.2026.01.046
Chaoqun Wu , Yi Chen , Minghui Yang , Yufei Tang , Yun Cheng
The network-structured TiBw/TA15 composites are promising for aerospace but difficult to micromachining. Minimum quantity lubrication (MQL) is attractive for composites machining, yet its effect on surface quality in TiBw/TA15 micromilling remains unclear. The multiphase microstructures of TiBw/TA15 induce brittle-plastic removal and accelerates tool wear. Consequently, the MQL lubrication and tool wear are tightly coupled in evaluating surface quality, the mechanistic elucidation of MQL and machining-parameter effects remain challenging. To address this gap, this study integrates the computational fluid dynamics (CFD) modeling of oil-mist delivery with finite-element analysis (FEA) of multiphase material removal to interpret the results of systematic micromilling experiments across increasing cutting distances. The results show that MQL improves surface quality relative to dry cutting by suppressing the irregular plastic flow of TA15, while TiBw fractures remain but contribute less to surface roughness. The parameter effects are stage-dependent: In initial wear (≤20 mm), radial cutting depth governs the surface roughness through lubrication effectiveness and tool edge geometry, and a moderate value of 60 μm is recommended. In stable wear (>20 mm), spindle speed becomes dominant by altering the lubricant residence and matrix plastic deformation, and the high value of 30,000 rpm is discouraged. A small feed rate (3 μm/tooth) is not recommended due to the intensified ploughing effect and tool wear. MQL ensures consistent surface roughness values remaining under 300 nm, even as tool wear occurs. These findings could provide critical guidance for precision machining of TiBw/TA15 composites.
网状结构TiBw/TA15复合材料在航空航天领域具有广阔的应用前景,但微加工难度较大。最小量润滑(MQL)在复合材料加工中很有吸引力,但其对TiBw/TA15微铣削表面质量的影响尚不清楚。TiBw/TA15的多相组织诱导脆性塑性去除,加速刀具磨损。因此,MQL润滑和刀具磨损在表面质量评价中是紧密耦合的,对MQL和加工参数影响的机理解释仍然具有挑战性。为了解决这一差距,本研究将油雾输送的计算流体动力学(CFD)建模与多相材料去除的有限元分析(FEA)相结合,以解释系统微铣削实验在增加切削距离时的结果。结果表明,相对于干切削,MQL通过抑制TA15的不规则塑性流动改善了表面质量,而TiBw断口仍然存在,但对表面粗糙度的影响较小。参数的影响是阶段相关的:在初始磨损(≤20 mm)时,径向切削深度通过润滑效果和刀具边缘几何形状来控制表面粗糙度,建议采用60 μm的适中值。在稳定磨损(> 20mm)时,通过改变润滑油停留和基体塑性变形,主轴转速成为主导,不鼓励30,000 rpm的高值。由于犁耕效应加剧,刀具磨损严重,不建议采用小进给速度(3 μm/齿)。MQL确保表面粗糙度值保持在300nm以下,即使发生刀具磨损。研究结果可为TiBw/TA15复合材料的精密加工提供重要指导。
{"title":"Effect of minimum quality lubrication on micromilling of TiBw/TA15 composites considering tool wear","authors":"Chaoqun Wu ,&nbsp;Yi Chen ,&nbsp;Minghui Yang ,&nbsp;Yufei Tang ,&nbsp;Yun Cheng","doi":"10.1016/j.jmapro.2026.01.046","DOIUrl":"10.1016/j.jmapro.2026.01.046","url":null,"abstract":"<div><div>The network-structured TiBw/TA15 composites are promising for aerospace but difficult to micromachining. Minimum quantity lubrication (MQL) is attractive for composites machining, yet its effect on surface quality in TiBw/TA15 micromilling remains unclear. The multiphase microstructures of TiBw/TA15 induce brittle-plastic removal and accelerates tool wear. Consequently, the MQL lubrication and tool wear are tightly coupled in evaluating surface quality, the mechanistic elucidation of MQL and machining-parameter effects remain challenging. To address this gap, this study integrates the computational fluid dynamics (CFD) modeling of oil-mist delivery with finite-element analysis (FEA) of multiphase material removal to interpret the results of systematic micromilling experiments across increasing cutting distances. The results show that MQL improves surface quality relative to dry cutting by suppressing the irregular plastic flow of TA15, while TiBw fractures remain but contribute less to surface roughness. The parameter effects are stage-dependent: In initial wear (≤20 mm), radial cutting depth governs the surface roughness through lubrication effectiveness and tool edge geometry, and a moderate value of 60 μm is recommended. In stable wear (&gt;20 mm), spindle speed becomes dominant by altering the lubricant residence and matrix plastic deformation, and the high value of 30,000 rpm is discouraged. A small feed rate (3 μm/tooth) is not recommended due to the intensified ploughing effect and tool wear. MQL ensures consistent surface roughness values remaining under 300 nm, even as tool wear occurs. These findings could provide critical guidance for precision machining of TiBw/TA15 composites.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 271-285"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981114","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
Thermal effects on the material removal mechanism in laser-assisted milling of CFRP 激光铣削CFRP中热效应对材料去除机理的影响
IF 6.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-02-15 Epub Date: 2026-01-15 DOI: 10.1016/j.jmapro.2026.01.033
Chao Zhang , Yinghui Ren , Maojun Li , Chengyang Yu , Minghui Liao , Xiaolin Yu , Qiding Yang
The anisotropy of carbon fiber reinforced plastic (CFRP) leads to an inhomogeneous heat-affected zone (HAZ, the laser-irradiated region with thermal-induced structural and property degradation), which significantly impacts the stability and quality of laser-assisted robotic milling (L-ARM). Based on the heat conduction model and robotic milling platform, this study developed novel finite element models of different zones of HAZ, including matrix recession zone (MRZ, with severe matrix decomposition) and transition zone (TZ, with partial matrix degradation), to reveal the material removal mechanism under different thermal effects. The results show that the energy per unit length (El) and temperature distribution significantly impact the morphology and extent of HAZ. Matrix degradation and fiber rebound in the MRZ lead to burr formation. Fiber shearing in the TZ under minor thermal effects produces superior surface quality. Conversely, major thermal effect results in fiber bending and matrix cracks. Notably, cutting force fluctuations are higher in the TZ than in the MRZ, reaching a maximum of 31.74 N during milling of TZ under minor thermal effects (El = 150 J/mm), which significantly affects the stability and quality of robotic milling.
碳纤维增强塑料(CFRP)的各向异性导致其热影响区(HAZ)不均匀,这对激光辅助机器人铣削(L-ARM)的稳定性和质量产生了重大影响。基于热传导模型和机器人铣削平台,建立了热影响区不同区域的有限元模型,包括基体退化区(MRZ,基体严重分解)和过渡区(TZ,基体部分降解),揭示了不同热效应下材料的去除机理。结果表明,单位长度能量(El)和温度分布对热影响区形态和程度有显著影响。MRZ中的基体降解和纤维回弹导致毛刺的形成。在热效应较小的情况下,纤维在TZ中剪切产生优异的表面质量。相反,主要的热效应导致纤维弯曲和基体裂纹。值得注意的是,在热效应较小(El = 150 J/mm)的情况下,铣削TZ时的切削力波动幅度比MRZ大,最大可达31.74 N,显著影响机器人铣削的稳定性和质量。
{"title":"Thermal effects on the material removal mechanism in laser-assisted milling of CFRP","authors":"Chao Zhang ,&nbsp;Yinghui Ren ,&nbsp;Maojun Li ,&nbsp;Chengyang Yu ,&nbsp;Minghui Liao ,&nbsp;Xiaolin Yu ,&nbsp;Qiding Yang","doi":"10.1016/j.jmapro.2026.01.033","DOIUrl":"10.1016/j.jmapro.2026.01.033","url":null,"abstract":"<div><div>The anisotropy of carbon fiber reinforced plastic (CFRP) leads to an inhomogeneous heat-affected zone (HAZ, the laser-irradiated region with thermal-induced structural and property degradation), which significantly impacts the stability and quality of laser-assisted robotic milling (L-ARM). Based on the heat conduction model and robotic milling platform, this study developed novel finite element models of different zones of HAZ, including matrix recession zone (MRZ, with severe matrix decomposition) and transition zone (TZ, with partial matrix degradation), to reveal the material removal mechanism under different thermal effects. The results show that the energy per unit length (<em>E</em><sub><em>l</em></sub>) and temperature distribution significantly impact the morphology and extent of HAZ. Matrix degradation and fiber rebound in the MRZ lead to burr formation. Fiber shearing in the TZ under minor thermal effects produces superior surface quality. Conversely, major thermal effect results in fiber bending and matrix cracks. Notably, cutting force fluctuations are higher in the TZ than in the MRZ, reaching a maximum of 31.74 N during milling of TZ under minor thermal effects (<em>E</em><sub><em>l</em></sub> = 150 J/mm), which significantly affects the stability and quality of robotic milling.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 199-216"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981210","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
Self-calibration method for rotary axis geometric errors in five-axis machine tools using gear-shaped workpieces 用齿轮形工件标定五轴机床旋转轴几何误差的方法
IF 6.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-02-15 Epub Date: 2026-01-20 DOI: 10.1016/j.jmapro.2026.01.041
Kejian Chen , Sitong Xiang , Juntao Ni , Hainan Zhang , Jianguo Yang
With the continuous advancement of manufacturing precision requirements, the importance of machine tool accuracy inspection has become increasingly prominent. This study proposes a self-calibration approach for rotary axis geometric errors using a gear-shaped workpiece. By designing a gear-shaped workpiece featuring 12 arc surfaces, an error identification model is established, the study focuses on the contributions of the machine tool's linear axes and C-axis geometric errors to the probing deviations. Combined with on-machine measurement technology using a touch-trigger probe, this method achieves decoupled identification of linear axis errors, workpiece geometric errors, and rotary axis geometric errors. Specifically, the rotary axis geometric errors include 4 position-independent geometric errors (PIGEs) and 6 position-dependent geometric errors (PDGEs). The workpiece incorporates square groove features to facilitate re-clamping and alignment, enhancing the efficiency of periodic accuracy calibration. The proposed method's effectiveness is further confirmed through uncertainty analysis and comparative experimental verification against ball-bar and artifact-based identification methods.
随着制造精度要求的不断提高,机床精度检测的重要性日益突出。提出了一种基于齿轮形工件的旋转轴几何误差自校正方法。通过设计具有12个圆弧面的齿轮形工件,建立了误差辨识模型,重点研究了机床直线轴和c轴几何误差对测头误差的贡献。该方法结合使用触摸触发探头的机上测量技术,实现了对直线轴误差、工件几何误差和旋转轴几何误差的解耦辨识。其中,旋转轴几何误差包括4个位置无关几何误差(PIGEs)和6个位置相关几何误差(PDGEs)。工件采用方槽特征,便于重新夹紧和对准,提高了周期性精度校准的效率。通过不确定度分析以及与基于球棒和伪像的识别方法的对比实验验证,进一步证实了该方法的有效性。
{"title":"Self-calibration method for rotary axis geometric errors in five-axis machine tools using gear-shaped workpieces","authors":"Kejian Chen ,&nbsp;Sitong Xiang ,&nbsp;Juntao Ni ,&nbsp;Hainan Zhang ,&nbsp;Jianguo Yang","doi":"10.1016/j.jmapro.2026.01.041","DOIUrl":"10.1016/j.jmapro.2026.01.041","url":null,"abstract":"<div><div>With the continuous advancement of manufacturing precision requirements, the importance of machine tool accuracy inspection has become increasingly prominent. This study proposes a self-calibration approach for rotary axis geometric errors using a gear-shaped workpiece. By designing a gear-shaped workpiece featuring 12 arc surfaces, an error identification model is established, the study focuses on the contributions of the machine tool's linear axes and C-axis geometric errors to the probing deviations. Combined with on-machine measurement technology using a touch-trigger probe, this method achieves decoupled identification of linear axis errors, workpiece geometric errors, and rotary axis geometric errors. Specifically, the rotary axis geometric errors include 4 position-independent geometric errors (PIGEs) and 6 position-dependent geometric errors (PDGEs). The workpiece incorporates square groove features to facilitate re-clamping and alignment, enhancing the efficiency of periodic accuracy calibration. The proposed method's effectiveness is further confirmed through uncertainty analysis and comparative experimental verification against ball-bar and artifact-based identification methods.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 429-441"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024735","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
Viscoelastic modeling and mechanism analysis of unbalanced filling in geometrically balanced injection molds 几何平衡注射模不平衡充型的粘弹性建模及机理分析
IF 6.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-02-15 Epub Date: 2026-01-19 DOI: 10.1016/j.jmapro.2026.01.019
Shaozhen Hua, Hui Li, Huabo Liu
Unbalanced filling in injection molding of geometrically balanced molds is a bad phenomenon that leads defects and has not been fully understanding. In this work, numerical simulation technique is taken to explore unbalanced filling. The melt during filling is considered to be incompressible, non-isothermal and viscoelastic fluids with Giesekus viscoelastic model to described its rheological character. A coupled finite volume method (FVM) and moving particle simulation (MPS) method was developed. Melt and air flow in cavity are treated as a whole flow field and solved by FVM, while the melt front is captured by the moving particles method. A benchmark case for the MPS method was then used to validate the developed algorithm. Additionally, the melt front progression, gate pressure, temperature distribution, and viscoelastic characteristics during injection molding were simulated and compared to experimental results or other numerical results. Results demonstrate that the developed algorithm can accurately simulate the non-isothermal viscoelastic injection molding process of the melt. Subsequently, the developed algorithm was applied to simulate both balanced and unbalanced filling processes during injection molding. Analysis of shear rate, temperature, and the first and second normal stress differences confirmed the validity of the established theory that shear-induced heating drives unbalanced filling. Furthermore, numerical results demonstrated that in tapered tubular runners, the first normal stress difference promotes balanced flow in naturally balanced runner systems, while the second normal stress difference induces unbalanced filling.
几何平衡模具注射成型中的不平衡填充是一种导致缺陷的不良现象,目前尚未得到充分认识。在这项工作中,采用数值模拟技术来研究不平衡填充。将填充过程中的熔体视为不可压缩、非等温粘弹性流体,用Giesekus粘弹性模型描述其流变特性。提出了一种有限体积法(FVM)和运动粒子模拟(MPS)的耦合方法。将熔体和空腔内空气流动作为一个整体流场,采用FVM方法求解,熔体前缘采用运动粒子法捕获。然后使用MPS方法的基准案例来验证所开发的算法。此外,还模拟了注射成型过程中熔体前缘进程、浇口压力、温度分布和粘弹性特性,并与实验结果或其他数值结果进行了比较。结果表明,该算法能够准确地模拟熔体的非等温粘弹性注射成型过程。随后,将所开发的算法应用于模拟注射成型过程中的平衡和不平衡填充过程。对剪切速率、温度和第一、第二正应力差的分析证实了剪切加热驱动不平衡充填的理论的有效性。此外,数值结果表明,在锥形管流道中,第一个法向应力差促进了自然平衡流道系统的平衡流动,而第二个法向应力差导致了不平衡填充。
{"title":"Viscoelastic modeling and mechanism analysis of unbalanced filling in geometrically balanced injection molds","authors":"Shaozhen Hua,&nbsp;Hui Li,&nbsp;Huabo Liu","doi":"10.1016/j.jmapro.2026.01.019","DOIUrl":"10.1016/j.jmapro.2026.01.019","url":null,"abstract":"<div><div>Unbalanced filling in injection molding of geometrically balanced molds is a bad phenomenon that leads defects and has not been fully understanding. In this work, numerical simulation technique is taken to explore unbalanced filling. The melt during filling is considered to be incompressible, non-isothermal and viscoelastic fluids with Giesekus viscoelastic model to described its rheological character. A coupled finite volume method (FVM) and moving particle simulation (MPS) method was developed. Melt and air flow in cavity are treated as a whole flow field and solved by FVM, while the melt front is captured by the moving particles method. A benchmark case for the MPS method was then used to validate the developed algorithm. Additionally, the melt front progression, gate pressure, temperature distribution, and viscoelastic characteristics during injection molding were simulated and compared to experimental results or other numerical results. Results demonstrate that the developed algorithm can accurately simulate the non-isothermal viscoelastic injection molding process of the melt. Subsequently, the developed algorithm was applied to simulate both balanced and unbalanced filling processes during injection molding. Analysis of shear rate, temperature, and the first and second normal stress differences confirmed the validity of the established theory that shear-induced heating drives unbalanced filling. Furthermore, numerical results demonstrated that in tapered tubular runners, the first normal stress difference promotes balanced flow in naturally balanced runner systems, while the second normal stress difference induces unbalanced filling.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 409-428"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024734","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
Laser cladding process optimization via multimodal generative prediction and reinforcement learning 基于多模态生成预测和强化学习的激光熔覆工艺优化
IF 6.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-02-15 Epub Date: 2026-01-13 DOI: 10.1016/j.jmapro.2026.01.004
Yixuan Dong , Tonghui Wang , Chuang Guan , Yiqi Wang , Jinsu Yu , Tianbiao Yu
Laser cladding (LC) is widely used for high-performance surface enhancement and component repair, with its processing quality highly dependent on complex parameter configurations. However, for LC-applied high-entropy alloy (HEA) coatings, the high cost of sample acquisition and the limitations of traditional response surface methods make it difficult to achieve accurate optimization under small-sample scenarios. This study proposes a laser cladding process parameter optimization method for MoNbTaTiZr powder, integrating multimodal surrogate modeling with reinforcement learning. A conditional generative adversarial network (cGAN) is employed to generate cross-sectional feature images of the cladding layer, which are further processed using a convolutional neural network (CNN) combined with a multi-task architecture to jointly predict multiple performance metrics, including dilution rate, shape factor, and microhardness. Based on this framework, this study proposes a Soft Actor-Critic algorithm with perturbation-aware replay optimization (PRO-SAC) method, which incorporates policy perturbation sensitivity, Temporal Difference (TD) error, and Pareto-front information of samples to jointly drive experience replay, thereby improving the learning efficiency and stability of process parameter optimization strategies. Experimental results show that the proposed prediction model achieves correlation coefficients above 0.97 for all quality indicators. Compared with other classical methods, the PRO-SAC optimization results exhibit superior performance across multiple evaluation metrics. Under the constraint of maintaining the shape factor, the microhardness and dilution rate of the cladding layer are improved by 11.3 % and 0.24 %, respectively, relative to the best values in the existing training dataset, confirming the effectiveness and engineering adaptability of the proposed method for laser cladding parameter optimization.
激光熔覆(LC)广泛应用于高性能表面增强和部件修复,其加工质量高度依赖于复杂的参数配置。然而,对于lc应用的高熵合金(HEA)涂层,由于样品采集成本高和传统响应面方法的局限性,难以在小样本情况下实现精确的优化。本研究提出了一种将多模态代理建模与强化学习相结合的MoNbTaTiZr粉末激光熔覆工艺参数优化方法。采用条件生成对抗网络(conditional generative adversarial network, cGAN)生成熔覆层的截面特征图像,并使用卷积神经网络(convolutional neural network, CNN)结合多任务架构对其进行进一步处理,共同预测包括稀释率、形状因子和显微硬度在内的多个性能指标。基于此框架,本文提出了一种带有扰动感知重播优化(PRO-SAC)方法的软Actor-Critic算法,该算法将策略扰动敏感性、时间差(TD)误差和样本的Pareto-front信息结合起来共同驱动经验重播,从而提高了过程参数优化策略的学习效率和稳定性。实验结果表明,所提出的预测模型各质量指标的相关系数均在0.97以上。与其他经典方法相比,PRO-SAC优化结果在多个评价指标上表现出优越的性能。在保持形状因子的约束下,熔覆层的显微硬度和稀释率相对于现有训练数据集中的最佳值分别提高了11.3%和0.24%,验证了所提方法用于激光熔覆参数优化的有效性和工程适应性。
{"title":"Laser cladding process optimization via multimodal generative prediction and reinforcement learning","authors":"Yixuan Dong ,&nbsp;Tonghui Wang ,&nbsp;Chuang Guan ,&nbsp;Yiqi Wang ,&nbsp;Jinsu Yu ,&nbsp;Tianbiao Yu","doi":"10.1016/j.jmapro.2026.01.004","DOIUrl":"10.1016/j.jmapro.2026.01.004","url":null,"abstract":"<div><div>Laser cladding (LC) is widely used for high-performance surface enhancement and component repair, with its processing quality highly dependent on complex parameter configurations. However, for LC-applied high-entropy alloy (HEA) coatings, the high cost of sample acquisition and the limitations of traditional response surface methods make it difficult to achieve accurate optimization under small-sample scenarios. This study proposes a laser cladding process parameter optimization method for MoNbTaTiZr powder, integrating multimodal surrogate modeling with reinforcement learning. A conditional generative adversarial network (cGAN) is employed to generate cross-sectional feature images of the cladding layer, which are further processed using a convolutional neural network (CNN) combined with a multi-task architecture to jointly predict multiple performance metrics, including dilution rate, shape factor, and microhardness. Based on this framework, this study proposes a Soft Actor-Critic algorithm with perturbation-aware replay optimization (PRO-SAC) method, which incorporates policy perturbation sensitivity, Temporal Difference (TD) error, and Pareto-front information of samples to jointly drive experience replay, thereby improving the learning efficiency and stability of process parameter optimization strategies. Experimental results show that the proposed prediction model achieves correlation coefficients above 0.97 for all quality indicators. Compared with other classical methods, the PRO-SAC optimization results exhibit superior performance across multiple evaluation metrics. Under the constraint of maintaining the shape factor, the microhardness and dilution rate of the cladding layer are improved by 11.3 % and 0.24 %, respectively, relative to the best values in the existing training dataset, confirming the effectiveness and engineering adaptability of the proposed method for laser cladding parameter optimization.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 50-64"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981202","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
An online chatter detection for milling based on a novel convolutional neural network and small probability hypothesis method 基于卷积神经网络和小概率假设方法的铣削颤振在线检测
IF 6.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-02-15 Epub Date: 2026-01-13 DOI: 10.1016/j.jmapro.2026.01.012
Yongliang Lu , Jun Zhao , Anhai Li , Xujie Tang , Junfu Liu
Milling chatter can seriously reduce the surface quality and production efficiency of the workpiece being machined, so accurate chatter detection is essential. In recent years, convolutional neural networks (CNNs) have been extensively employed for chatter detection, demonstrating promising effectiveness. However, the quality of data labeling and the training process substantially affect the generalization and accuracy of CNNs. To overcome the above limitations, this paper proposed a novel hybrid deep convolutional neural network (HDCNN) named Chatter-CNN for online chatter detection in milling processes. The model integrates an Inception-Chatter module and a Squeeze-and-Excitation Residual Mutual Information (SR-MI) block, utilizing both milling force and vibration acceleration signals during datasets construction. Furthermore, an early chatter detection method based on the small-probability hypothesis combined with cumulative sum (CUSUM) is developed. Comparative milling experiments are conducted on a wedge-shaped workpiece and a thin-walled workpiece under different cutting parameters, cutting edges and tool overhang lengths to verify the detection performance of the proposed Chatter-CNN. Experimental results demonstrate that the proposed Chatter-CNN achieves 99.9 % / 94.7 % (validation/test) on the wedge-shaped workpiece and 99.8 % / 94.2 % (validation/test) on the thin-walled workpiece, outperforming existing CNNs. Further experimental results combining the proposed early detection method show that Chatter-CNN outperforms existing CNNs and threshold-based techniques by more accurately identifying machining states, including transition states, and enabling earlier detection of chatter onset, thereby facilitating chatter suppression.
铣削颤振会严重降低被加工工件的表面质量和生产效率,因此精确的颤振检测至关重要。近年来,卷积神经网络(cnn)被广泛应用于颤振检测,显示出良好的效果。然而,数据标注和训练过程的质量极大地影响了cnn的泛化和准确性。为了克服上述局限性,本文提出了一种新的混合深度卷积神经网络(HDCNN),命名为chatter - cnn,用于铣削过程中的在线颤振检测。该模型集成了一个启动-颤振模块和一个挤压-激励剩余互信息(SR-MI)模块,在数据集构建过程中同时利用铣削力和振动加速度信号。在此基础上,提出了一种基于小概率假设与累积和相结合的早期颤振检测方法。通过对楔形工件和薄壁工件在不同切削参数、切削刃和刀具悬垂长度下的铣削对比实验,验证了该方法的检测性能。实验结果表明,所提出的Chatter-CNN在楔形工件上达到99.9% / 94.7%(验证/测试),在薄壁工件上达到99.8% / 94.2%(验证/测试),优于现有的cnn。结合提出的早期检测方法,进一步的实验结果表明,通过更准确地识别加工状态,包括过渡状态,更早地检测颤振的发生,从而有利于颤振抑制,chatter - cnn优于现有的cnn和基于阈值的技术。
{"title":"An online chatter detection for milling based on a novel convolutional neural network and small probability hypothesis method","authors":"Yongliang Lu ,&nbsp;Jun Zhao ,&nbsp;Anhai Li ,&nbsp;Xujie Tang ,&nbsp;Junfu Liu","doi":"10.1016/j.jmapro.2026.01.012","DOIUrl":"10.1016/j.jmapro.2026.01.012","url":null,"abstract":"<div><div>Milling chatter can seriously reduce the surface quality and production efficiency of the workpiece being machined, so accurate chatter detection is essential. In recent years, convolutional neural networks (CNNs) have been extensively employed for chatter detection, demonstrating promising effectiveness. However, the quality of data labeling and the training process substantially affect the generalization and accuracy of CNNs. To overcome the above limitations, this paper proposed a novel hybrid deep convolutional neural network (HDCNN) named Chatter-CNN for online chatter detection in milling processes. The model integrates an Inception-Chatter module and a Squeeze-and-Excitation Residual Mutual Information (SR-MI) block, utilizing both milling force and vibration acceleration signals during datasets construction. Furthermore, an early chatter detection method based on the small-probability hypothesis combined with cumulative sum (CUSUM) is developed. Comparative milling experiments are conducted on a wedge-shaped workpiece and a thin-walled workpiece under different cutting parameters, cutting edges and tool overhang lengths to verify the detection performance of the proposed Chatter-CNN. Experimental results demonstrate that the proposed Chatter-CNN achieves 99.9 % / 94.7 % (validation/test) on the wedge-shaped workpiece and 99.8 % / 94.2 % (validation/test) on the thin-walled workpiece, outperforming existing CNNs. Further experimental results combining the proposed early detection method show that Chatter-CNN outperforms existing CNNs and threshold-based techniques by more accurately identifying machining states, including transition states, and enabling earlier detection of chatter onset, thereby facilitating chatter suppression.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 65-106"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981205","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
Oxidation and photothermal energy conversion at the laser-induced vapor–liquid interface during laser spot welding 激光点焊过程中气液界面氧化与光热能量转换
IF 6.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-02-15 Epub Date: 2026-01-15 DOI: 10.1016/j.jmapro.2026.01.031
Tao Liu , Shun Xie , Jianglin Zou , Jing Wang , Kaikai Shi , Yuxuan Zhang , Qiang Wu
Studying the oxidation behavior on the molten pool surface during laser spot welding in an atmospheric environment is important for developing molten pool protection strategies and for understanding the laser-induced optical-to-thermal energy conversion at the vapor–liquid interface. This study shows that, under a fixed laser exposure duration, as the laser power increases, the solid-phase heating stage is markedly shortened, the melting stage first lengthens and then shortens, and the vaporization stage continues to extend. Meanwhile, the total laser absorptivity of the metal exhibits a non-monotonic trend, decreasing first and then increasing, and the absorptivity in air is consistently higher than that in argon. Under atmospheric conditions, surface oxidation of the molten pool occurs predominantly during the melting stage, where oxidation of the liquid surface can significantly enhance absorptivity. At low laser power without a vaporization stage, the prolonged melting stage leads to a peak absorptivity of the liquid surface in air that is approximately 14.7% higher than that in argon. At high laser power, laser-induced evaporation suppresses further surface oxidation, causing the absorptivity of the vapor–liquid interface to decrease with increasing power. In addition, the shortening of the melting stage with increasing high laser power is a primary reason why both the extent of surface oxidation and the corresponding absorptivity increment become negligible under atmospheric conditions. Overall, this work elucidates the stage-dependent roles of vapor–liquid interfacial oxidation during laser spot welding and provides a theoretical basis for improving energy coupling efficiency and for designing optimal molten pool protection strategies in high-precision laser melting manufacturing applications.
研究大气环境下激光点焊过程中熔池表面的氧化行为,对于制定熔池保护策略和理解激光诱导的气液界面光热转换具有重要意义。研究表明,在一定的激光照射时间下,随着激光功率的增大,固相加热阶段明显缩短,熔化阶段先变长后变短,汽化阶段持续延长。同时,金属的激光总吸收率呈先减小后增大的非单调趋势,在空气中的吸收率始终高于氩气中的吸收率。在大气条件下,熔池表面氧化主要发生在熔化阶段,此时液面氧化可显著提高吸收率。在没有汽化阶段的低激光功率下,熔化阶段延长导致液体表面在空气中的峰值吸收率比在氩气中的峰值高约14.7%。在高激光功率下,激光诱导的蒸发抑制了进一步的表面氧化,导致气液界面的吸收率随着功率的增加而降低。此外,随着激光功率的增加,熔化阶段的缩短是大气条件下表面氧化程度和相应的吸收率增量可以忽略不计的主要原因。总的来说,本研究阐明了激光点焊过程中气液界面氧化的阶段依赖作用,为高精度激光熔化制造应用中提高能量耦合效率和设计最佳熔池保护策略提供了理论基础。
{"title":"Oxidation and photothermal energy conversion at the laser-induced vapor–liquid interface during laser spot welding","authors":"Tao Liu ,&nbsp;Shun Xie ,&nbsp;Jianglin Zou ,&nbsp;Jing Wang ,&nbsp;Kaikai Shi ,&nbsp;Yuxuan Zhang ,&nbsp;Qiang Wu","doi":"10.1016/j.jmapro.2026.01.031","DOIUrl":"10.1016/j.jmapro.2026.01.031","url":null,"abstract":"<div><div>Studying the oxidation behavior on the molten pool surface during laser spot welding in an atmospheric environment is important for developing molten pool protection strategies and for understanding the laser-induced optical-to-thermal energy conversion at the vapor–liquid interface. This study shows that, under a fixed laser exposure duration, as the laser power increases, the solid-phase heating stage is markedly shortened, the melting stage first lengthens and then shortens, and the vaporization stage continues to extend. Meanwhile, the total laser absorptivity of the metal exhibits a non-monotonic trend, decreasing first and then increasing, and the absorptivity in air is consistently higher than that in argon. Under atmospheric conditions, surface oxidation of the molten pool occurs predominantly during the melting stage, where oxidation of the liquid surface can significantly enhance absorptivity. At low laser power without a vaporization stage, the prolonged melting stage leads to a peak absorptivity of the liquid surface in air that is approximately 14.7% higher than that in argon. At high laser power, laser-induced evaporation suppresses further surface oxidation, causing the absorptivity of the vapor–liquid interface to decrease with increasing power. In addition, the shortening of the melting stage with increasing high laser power is a primary reason why both the extent of surface oxidation and the corresponding absorptivity increment become negligible under atmospheric conditions. Overall, this work elucidates the stage-dependent roles of vapor–liquid interfacial oxidation during laser spot welding and provides a theoretical basis for improving energy coupling efficiency and for designing optimal molten pool protection strategies in high-precision laser melting manufacturing applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 188-198"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981208","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 review on tufting technology for 3D preforms: Manufacturing, process parameters and performance implications 三维预成形簇封技术综述:制造、工艺参数和性能影响
IF 6.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-02-15 Epub Date: 2026-01-19 DOI: 10.1016/j.jmapro.2026.01.022
Jian Hu , Hao Shen , Xavier Legrand , Peng Wang
Tufting is a promising technology for reinforcing composite materials, offering notable advantages in both performance and cost-effectiveness. It effectively improves the delamination resistance and impact tolerance of multi-layered composite structures, making it highly applicable across a range of industries, including transportation, construction, energy, and defence. In recent years, significant advancements have been made in the development of tufted multi-layered composites. Nevertheless, there remain gaps in the systematic understanding of the tufting process. This review provides an overview of the current stage of tufting technology, including its definition, key tufting parameters, and the potential damage to tufted composites. Additionally, the paper summarises current research on the forming and simulation of tufted preforms. Future research efforts should focus on optimising the tufting process, standardising techniques, and expanding its industrial applications.
簇绒是一种很有前途的复合材料增强技术,在性能和成本效益方面都有显著的优势。它有效地提高了多层复合材料结构的抗分层能力和抗冲击能力,使其在交通运输、建筑、能源和国防等一系列行业中具有很高的适用性。近年来,簇状多层复合材料的发展取得了重大进展。然而,在对簇绒过程的系统认识方面仍然存在差距。本文综述了现阶段簇绒技术的发展概况,包括簇绒技术的定义、关键簇绒参数以及簇绒复合材料的潜在危害。此外,本文还对簇状预制件的成形和仿真研究现状进行了综述。未来的研究工作应集中在优化簇绒工艺、标准化技术和扩大其工业应用上。
{"title":"A review on tufting technology for 3D preforms: Manufacturing, process parameters and performance implications","authors":"Jian Hu ,&nbsp;Hao Shen ,&nbsp;Xavier Legrand ,&nbsp;Peng Wang","doi":"10.1016/j.jmapro.2026.01.022","DOIUrl":"10.1016/j.jmapro.2026.01.022","url":null,"abstract":"<div><div>Tufting is a promising technology for reinforcing composite materials, offering notable advantages in both performance and cost-effectiveness. It effectively improves the delamination resistance and impact tolerance of multi-layered composite structures, making it highly applicable across a range of industries, including transportation, construction, energy, and defence. In recent years, significant advancements have been made in the development of tufted multi-layered composites. Nevertheless, there remain gaps in the systematic understanding of the tufting process. This review provides an overview of the current stage of tufting technology, including its definition, key tufting parameters, and the potential damage to tufted composites. Additionally, the paper summarises current research on the forming and simulation of tufted preforms. Future research efforts should focus on optimising the tufting process, standardising techniques, and expanding its industrial applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 377-395"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024731","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
High-performance CoCrFeNi/6061 aluminum matrix composites fabricated by cold spray-friction stir processing composite additive manufacturing 采用冷喷涂-搅拌摩擦复合增材制造制备高性能CoCrFeNi/6061铝基复合材料
IF 6.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-02-15 Epub Date: 2026-01-19 DOI: 10.1016/j.jmapro.2026.01.048
Peng Han , Jiaxing Duan , Qianzhi Ma , Jia Lin , Fengming Qiang , Wen Wang , Ke Qiao , Kuaishe Wang
To overcome the poor strength-ductility trade-off in ceramic particle-reinforced aluminum matrix composites (AMCs), this study fabricated CoCrFeNi particle-reinforced AMCs using cold spray and cold spray-friction stir processing composite additive manufacturing (CFAM) technology, respectively. The microstructures and mechanical properties of the AMCs were systematically optimized through a short-time T6 heat treatment. A comprehensive microstructural characterization of the AMCs was performed using X-ray diffraction, scanning electron microscopy, electron backscatter diffraction, and transmission electron microscopy. The tensile strength was evaluated and the strengthening mechanism was determined. The results indicated that the cold-sprayed AMCs contained significant porosity and a highly inhomogeneous grain structure. The CoCrFeNi/Al interfaces were primarily characterized by mechanical bonding, with no significant interfacial reactions observed. Comparatively, the AMCs fabricated by CFAM demonstrated significantly refined, homogenized, and densified microstructures, with an average grain size of 1.46 μm. Enhanced elemental interdiffusion occurred at the CoCrFeNi/Al interface, and numerous intermetallic compounds, specifically Al7Cr and Al9(Co,Fe,Ni)2, were found to be homogeneously dispersed within the Al matrix. After short-time T6 heat treatment, the average grain size of the AMCs fabricated by CFAM experienced slight growth, reaching an average of 1.92 μm. Concurrently, interfacial reaction at the CoCrFeNi/Al interface intensified, leading to the formation of a dual-layer interfacial reaction zone. This zone consisted of an inner layer enriched with α-Al(Co,Cr,Fe,Ni)Si and an outer layer enriched with Al9(Co,Fe,Ni)2 and Al13(Co,Fe,Ni)4. Meanwhile, the tensile strength of the AMCs fabricated by CFAM improved by 98 MPa compared to the pre-heat-treated state, reaching 368 MPa. This enhancement was primarily attributed to the short-time T6 heat treatment achieving concurrent optimization of the CoCrFeNi/Al interfacial reaction products and the precipitated phase within the Al matrix, thereby achieving excellent strength and elongation in the AMCs. In summary, this study developed an effective approach for fabricating high-performance AMCs reinforced with CoCrFeNi particles.
为了克服陶瓷颗粒增强铝基复合材料(AMCs)强度-延性差的问题,本研究分别采用冷喷涂和冷喷涂-搅拌摩擦加工复合增材制造(CFAM)技术制备了CoCrFeNi颗粒增强铝基复合材料。通过T6短时间热处理,系统优化了复合材料的组织和力学性能。利用x射线衍射、扫描电子显微镜、电子背散射衍射和透射电子显微镜对AMCs进行了全面的微观结构表征。评估了材料的抗拉强度,确定了强化机理。结果表明,冷喷涂后的碳纤维具有显著的孔隙率和高度不均匀的晶粒结构。CoCrFeNi/Al界面以机械键合为主,未观察到明显的界面反应。相比之下,CFAM制备的碳纤维具有明显的细化、均匀化和致密化的微观结构,平均晶粒尺寸为1.46 μm。元素间扩散增强发生在CoCrFeNi/Al界面,大量金属间化合物,特别是Al7Cr和Al9(Co,Fe,Ni)2,均匀分布在Al基体中。经过T6短时间热处理后,CFAM制备的碳纤维的平均晶粒尺寸略有增大,达到1.92 μm。同时,CoCrFeNi/Al界面处的界面反应增强,形成了双层界面反应区。该带由富含α-Al(Co,Cr,Fe,Ni)Si的内层和富含Al9(Co,Fe,Ni)2和Al13(Co,Fe,Ni)4的外层组成。同时,CFAM制备的碳纤维的抗拉强度比热处理前提高了98 MPa,达到了368 MPa。这种增强主要是由于短时间T6热处理同时优化了CoCrFeNi/Al界面反应产物和Al基体内的析出相,从而获得了优异的强度和伸长率。总之,本研究开发了一种制备CoCrFeNi颗粒增强高性能amc的有效方法。
{"title":"High-performance CoCrFeNi/6061 aluminum matrix composites fabricated by cold spray-friction stir processing composite additive manufacturing","authors":"Peng Han ,&nbsp;Jiaxing Duan ,&nbsp;Qianzhi Ma ,&nbsp;Jia Lin ,&nbsp;Fengming Qiang ,&nbsp;Wen Wang ,&nbsp;Ke Qiao ,&nbsp;Kuaishe Wang","doi":"10.1016/j.jmapro.2026.01.048","DOIUrl":"10.1016/j.jmapro.2026.01.048","url":null,"abstract":"<div><div>To overcome the poor strength-ductility trade-off in ceramic particle-reinforced aluminum matrix composites (AMCs), this study fabricated CoCrFeNi particle-reinforced AMCs using cold spray and cold spray-friction stir processing composite additive manufacturing (CFAM) technology, respectively. The microstructures and mechanical properties of the AMCs were systematically optimized through a short-time T6 heat treatment. A comprehensive microstructural characterization of the AMCs was performed using X-ray diffraction, scanning electron microscopy, electron backscatter diffraction, and transmission electron microscopy. The tensile strength was evaluated and the strengthening mechanism was determined. The results indicated that the cold-sprayed AMCs contained significant porosity and a highly inhomogeneous grain structure. The CoCrFeNi/Al interfaces were primarily characterized by mechanical bonding, with no significant interfacial reactions observed. Comparatively, the AMCs fabricated by CFAM demonstrated significantly refined, homogenized, and densified microstructures, with an average grain size of 1.46 μm. Enhanced elemental interdiffusion occurred at the CoCrFeNi/Al interface, and numerous intermetallic compounds, specifically Al<sub>7</sub>Cr and Al<sub>9</sub>(Co,Fe,Ni)<sub>2</sub>, were found to be homogeneously dispersed within the Al matrix. After short-time T6 heat treatment, the average grain size of the AMCs fabricated by CFAM experienced slight growth, reaching an average of 1.92 μm. Concurrently, interfacial reaction at the CoCrFeNi/Al interface intensified, leading to the formation of a dual-layer interfacial reaction zone. This zone consisted of an inner layer enriched with α-Al(<em>Co</em>,<em>Cr</em>,<em>Fe</em>,<em>Ni</em>)Si and an outer layer enriched with Al<sub>9</sub>(Co,Fe,Ni)<sub>2</sub> and Al<sub>13</sub>(Co,Fe,Ni)<sub>4</sub>. Meanwhile, the tensile strength of the AMCs fabricated by CFAM improved by 98 MPa compared to the pre-heat-treated state, reaching 368 MPa. This enhancement was primarily attributed to the short-time T6 heat treatment achieving concurrent optimization of the CoCrFeNi/Al interfacial reaction products and the precipitated phase within the Al matrix, thereby achieving excellent strength and elongation in the AMCs. In summary, this study developed an effective approach for fabricating high-performance AMCs reinforced with CoCrFeNi particles.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 347-360"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024739","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 study on mitigation of tunneling defects and investigation on the mechanical behavior of double-sided friction stir welded Al 2014 plates Al - 2014双面搅拌摩擦焊板隧道缺陷缓解及力学行为研究
IF 6.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-02-15 Epub Date: 2026-01-20 DOI: 10.1016/j.jmapro.2026.01.027
Raja Dharavathu , Kishora Shetty , Gopinath Muvvala
Friction stir welding (FSW) is a solid-state joining technique particularly effective for alloys that are difficult to weld by conventional fusion processes. However, welding of thick plates often necessitates robust kinematic systems, and steep thermal gradients can induce high flow stress near the tool tip, leading to tunneling or void defects. This study focuses on minimizing such defects and improving the mechanical performance of 8 mm thick 2014-T6 aluminum alloy joints produced by double-sided FSW. Process optimization was achieved by varying pin lengths, reducing welding speeds, and increasing the tool tilt angle from 0° to 2°, which enhanced plastic flow and material consolidation. Defect-free joints were obtained at welding speeds of 5, 10, and 20 mm/min with a rotational speed of 900 rpm and a 2° tilt angle. Despite the absence of macroscopic defects, the as-welded joints exhibited reduced tensile strength due to overaging and coarsening of Al2Cu precipitates within the nugget zone (NZ), as confirmed by TEM. Comprehensive microstructural characterization using optical microscopy SEM, EDS and EBSD revealed precipitate dissolution and dynamic recrystallization within the NZ. Post-weld heat treatment (PWHT), consisting of solution treatment at 500 °C followed by artificial aging at 160 °C for 18 h, significantly enhanced strength and hardness owing to the re-precipitation of semi-coherent θ phases, though with a marginal decrease in ductility. Tensile testing with 2D digital image correlation indicated a strain hardening exponent of 0.25 in the as-welded NZ and 0.12 after PWHT, reflecting a transition from localized to more uniform plastic deformation behavior.
搅拌摩擦焊(FSW)是一种固态连接技术,对传统熔合工艺难以焊接的合金特别有效。然而,厚板的焊接通常需要强大的运动系统,陡峭的热梯度会在刀尖附近引起高流动应力,导致隧道或空洞缺陷。本研究的重点是减少这些缺陷,提高双面摩擦焊生产的8mm厚2014-T6铝合金接头的力学性能。通过改变销钉长度、降低焊接速度、将刀具倾斜角度从0°增加到2°,实现了工艺优化,从而增强了塑性流动和材料固结。焊接速度为5、10和20 mm/min,转速为900 rpm,倾斜角度为2°,焊接接头无缺陷。透射电镜证实,尽管没有宏观缺陷,但由于熔核区(NZ)内Al2Cu析出物的过时效和粗化,焊接接头的抗拉强度降低。利用光学显微镜、扫描电镜、能谱仪和电子能谱仪对NZ进行了全面的微观结构表征,发现了析出物溶解和动态再结晶。焊后热处理(PWHT)由500°C固溶处理和160°C人工时效18 h组成,由于半相干θ′相的再析出,强度和硬度显著提高,但塑性略有下降。二维数字图像相关拉伸试验表明,焊接状态下的NZ应变硬化指数为0.25,PWHT后的应变硬化指数为0.12,反映了局部塑性变形行为向更均匀塑性变形行为的转变。
{"title":"A study on mitigation of tunneling defects and investigation on the mechanical behavior of double-sided friction stir welded Al 2014 plates","authors":"Raja Dharavathu ,&nbsp;Kishora Shetty ,&nbsp;Gopinath Muvvala","doi":"10.1016/j.jmapro.2026.01.027","DOIUrl":"10.1016/j.jmapro.2026.01.027","url":null,"abstract":"<div><div>Friction stir welding (FSW) is a solid-state joining technique particularly effective for alloys that are difficult to weld by conventional fusion processes. However, welding of thick plates often necessitates robust kinematic systems, and steep thermal gradients can induce high flow stress near the tool tip, leading to tunneling or void defects. This study focuses on minimizing such defects and improving the mechanical performance of 8 mm thick 2014-T6 aluminum alloy joints produced by double-sided FSW. Process optimization was achieved by varying pin lengths, reducing welding speeds, and increasing the tool tilt angle from 0° to 2°, which enhanced plastic flow and material consolidation. Defect-free joints were obtained at welding speeds of 5, 10, and 20 mm/min with a rotational speed of 900 rpm and a 2° tilt angle. Despite the absence of macroscopic defects, the as-welded joints exhibited reduced tensile strength due to overaging and coarsening of Al<sub>2</sub>Cu precipitates within the nugget zone (NZ), as confirmed by TEM. Comprehensive microstructural characterization using optical microscopy SEM, EDS and EBSD revealed precipitate dissolution and dynamic recrystallization within the NZ. Post-weld heat treatment (PWHT), consisting of solution treatment at 500 °C followed by artificial aging at 160 °C for 18 h, significantly enhanced strength and hardness owing to the re-precipitation of semi-coherent <span><math><msup><mi>θ</mi><mo>′</mo></msup></math></span> phases, though with a marginal decrease in ductility. Tensile testing with 2D digital image correlation indicated a strain hardening exponent of 0.25 in the as-welded NZ and 0.12 after PWHT, reflecting a transition from localized to more uniform plastic deformation behavior.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 460-480"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024737","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
期刊
Journal of Manufacturing Processes
全部 Acc. Chem. Res. ACS Applied Bio Materials ACS Appl. Electron. Mater. ACS Appl. Energy Mater. ACS Appl. Mater. Interfaces ACS Appl. Nano Mater. ACS Appl. Polym. Mater. ACS BIOMATER-SCI ENG ACS Catal. ACS Cent. Sci. ACS Chem. Biol. ACS Chemical Health & Safety ACS Chem. Neurosci. ACS Comb. Sci. ACS Earth Space Chem. ACS Energy Lett. ACS Infect. Dis. ACS Macro Lett. ACS Mater. Lett. ACS Med. Chem. Lett. ACS Nano ACS Omega ACS Photonics ACS Sens. ACS Sustainable Chem. Eng. ACS Synth. Biol. Anal. Chem. BIOCHEMISTRY-US Bioconjugate Chem. BIOMACROMOLECULES Chem. Res. Toxicol. Chem. Rev. Chem. Mater. CRYST GROWTH DES ENERG FUEL Environ. Sci. Technol. Environ. Sci. Technol. Lett. Eur. J. Inorg. Chem. IND ENG CHEM RES Inorg. Chem. J. Agric. Food. Chem. J. Chem. Eng. Data J. Chem. Educ. J. Chem. Inf. Model. J. Chem. Theory Comput. J. Med. Chem. J. Nat. Prod. J PROTEOME RES J. Am. Chem. Soc. LANGMUIR MACROMOLECULES Mol. Pharmaceutics Nano Lett. Org. Lett. ORG PROCESS RES DEV ORGANOMETALLICS J. Org. Chem. J. Phys. Chem. J. Phys. Chem. A J. Phys. Chem. B J. Phys. Chem. C J. Phys. Chem. Lett. Analyst Anal. Methods Biomater. Sci. Catal. Sci. Technol. Chem. Commun. Chem. Soc. Rev. CHEM EDUC RES PRACT CRYSTENGCOMM Dalton Trans. Energy Environ. Sci. ENVIRON SCI-NANO ENVIRON SCI-PROC IMP ENVIRON SCI-WAT RES Faraday Discuss. Food Funct. Green Chem. Inorg. Chem. Front. Integr. Biol. J. Anal. At. Spectrom. J. Mater. Chem. A J. Mater. Chem. B J. Mater. Chem. C Lab Chip Mater. Chem. Front. Mater. Horiz. MEDCHEMCOMM Metallomics Mol. Biosyst. Mol. Syst. Des. Eng. Nanoscale Nanoscale Horiz. Nat. Prod. Rep. New J. Chem. Org. Biomol. Chem. Org. Chem. Front. PHOTOCH PHOTOBIO SCI PCCP Polym. Chem.
×
引用
GB/T 7714-2015
复制
MLA
复制
APA
复制
导出至
BibTeX EndNote RefMan NoteFirst NoteExpress
×
0
微信
客服QQ
Book学术公众号 扫码关注我们
反馈
×
意见反馈
请填写您的意见或建议
请填写您的手机或邮箱
×
提示
您的信息不完整,为了账户安全,请先补充。
现在去补充
×
提示
您因"违规操作"
具体请查看互助需知
我知道了
×
提示
现在去查看 取消
×
提示
确定
Book学术官方微信
Book学术文献互助
Book学术文献互助群
群 号:604180095
Book学术
文献互助 智能选刊 最新文献 互助须知 联系我们:info@booksci.cn
Book学术提供免费学术资源搜索服务,方便国内外学者检索中英文文献。致力于提供最便捷和优质的服务体验。
Copyright © 2023 Book学术 All rights reserved.
ghs 京公网安备 11010802042870号 京ICP备2023020795号-1