Yang Yang, Ying Cai, Yeo Jung Yoon, Hangbo Zhao, Satyandra K. Gupta
Abstract Robotic manipulators can be used to deposit materials on non-planar surfaces. Conventional sensor-based industrial robots can only work on stationary surfaces, relying on the scanned data prior to printing. As a result, performing depositions that involve changes in plane motion presents significant challenges. The deposition of conformal materials on a time-varying deformable surface requires the manipulators to update coordinates in real time on the plane for positioning and orientation. This can be achieved by employing multiple sensors for manipulator motion planning and control, in order to prevent collisions between the tool and the surface. In this paper, we propose simple tool center point calibration, initial point coordinate estimation, and a gap compensation scheme to combine real-time feedback control and direct conformal deposition. Combining these elements allows us to maintain a controlled gap between the tooltip and the deformable surface during the deposition. We test the efficacy of the proposed approach by printing a single layer of ink patterns with approximately 950 μm line width on a deformable surface. We also characterize the printing quality with different gaps and printing steps and show that sensor-based control is critical in smooth printing. Finally, the effects of changing the relative position of the tooltip, different surface colors, and laser sensor position are characterized.
{"title":"SENSOR-BASED PLANNING AND CONTROL FOR CONFORMAL DEPOSITION ON A DEFORMABLE SURFACE USING AN ARTICULATED INDUSTRIAL ROBOT","authors":"Yang Yang, Ying Cai, Yeo Jung Yoon, Hangbo Zhao, Satyandra K. Gupta","doi":"10.1115/1.4063560","DOIUrl":"https://doi.org/10.1115/1.4063560","url":null,"abstract":"Abstract Robotic manipulators can be used to deposit materials on non-planar surfaces. Conventional sensor-based industrial robots can only work on stationary surfaces, relying on the scanned data prior to printing. As a result, performing depositions that involve changes in plane motion presents significant challenges. The deposition of conformal materials on a time-varying deformable surface requires the manipulators to update coordinates in real time on the plane for positioning and orientation. This can be achieved by employing multiple sensors for manipulator motion planning and control, in order to prevent collisions between the tool and the surface. In this paper, we propose simple tool center point calibration, initial point coordinate estimation, and a gap compensation scheme to combine real-time feedback control and direct conformal deposition. Combining these elements allows us to maintain a controlled gap between the tooltip and the deformable surface during the deposition. We test the efficacy of the proposed approach by printing a single layer of ink patterns with approximately 950 μm line width on a deformable surface. We also characterize the printing quality with different gaps and printing steps and show that sensor-based control is critical in smooth printing. Finally, the effects of changing the relative position of the tooltip, different surface colors, and laser sensor position are characterized.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135667002","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Lily Raymond, Weijian Hua, Naima Valentin, Ryan Coulter, Erick Bandala, Kaitlin Leong, Jada Okaikoi, Yifei Jin
Abstract Creating multilayered channels for mimicking human blood vessels in thick tissues is the main challenge to overcome in organ biofabrication. Current three-dimensional (3D) printing strategies cannot effectively manufacture hollow channels with multiple layers. This study aims to propose a coaxial nozzle-assisted embedded 3D printing method in which core–shell filaments can be formed in a yield-stress matrix bath by extruding different ink materials through the corresponding channels. The materials selected for the core ink, shell ink, and matrix bath are Pluronic F127 (F127) and calcium chloride (CaCl2), sodium alginate (NaAlg), and poly(ethylene glycol) diacrylate (PEGDA) and nanoclay, respectively. After crosslinking the matrix bath and shell, the core layer made from the sacrificial ink (F127) is removed to generate a single-layered, hollow channel. In this work, the effects of ink material properties and operating conditions on core–shell filament formation have been systematically studied. The rheological and mechanical properties of the yield-stress matrix bath have been characterized as well. A thick tissue-like structure with embedded single-layered, hollow channels has been successfully printed for demonstration. Since it is feasible to design coaxial nozzles with a core–shell–shell architecture, the proposed method is technically extendable to create double-layered channels within a cellular tissue construct, accurately mimicking human blood vascular networks in thick tissues in the future.
{"title":"Coaxial Nozzle-Assisted Embedded 3D Printing of Single-Layered Channels Within a Yield-Stress Matrix Bath","authors":"Lily Raymond, Weijian Hua, Naima Valentin, Ryan Coulter, Erick Bandala, Kaitlin Leong, Jada Okaikoi, Yifei Jin","doi":"10.1115/1.4063452","DOIUrl":"https://doi.org/10.1115/1.4063452","url":null,"abstract":"Abstract Creating multilayered channels for mimicking human blood vessels in thick tissues is the main challenge to overcome in organ biofabrication. Current three-dimensional (3D) printing strategies cannot effectively manufacture hollow channels with multiple layers. This study aims to propose a coaxial nozzle-assisted embedded 3D printing method in which core–shell filaments can be formed in a yield-stress matrix bath by extruding different ink materials through the corresponding channels. The materials selected for the core ink, shell ink, and matrix bath are Pluronic F127 (F127) and calcium chloride (CaCl2), sodium alginate (NaAlg), and poly(ethylene glycol) diacrylate (PEGDA) and nanoclay, respectively. After crosslinking the matrix bath and shell, the core layer made from the sacrificial ink (F127) is removed to generate a single-layered, hollow channel. In this work, the effects of ink material properties and operating conditions on core–shell filament formation have been systematically studied. The rheological and mechanical properties of the yield-stress matrix bath have been characterized as well. A thick tissue-like structure with embedded single-layered, hollow channels has been successfully printed for demonstration. Since it is feasible to design coaxial nozzles with a core–shell–shell architecture, the proposed method is technically extendable to create double-layered channels within a cellular tissue construct, accurately mimicking human blood vascular networks in thick tissues in the future.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135667440","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Vivian Wong, Sang Hun Kim, Junyoung Park, Jinkyoo Park, Kincho Law
Abstract The interrupting swap-allowed blocking job shop problem (ISBJSSP) is a complex scheduling problem that is able to model many manufacturing planning and logistics applications realistically by addressing both the lack of storage capacity and unforeseen production interruptions. Subjected to random disruptions due to machine malfunction or maintenance, industry production settings often choose to adopt dispatching rules to enable adaptive, real-time re-scheduling, rather than traditional methods that require costly re-computation on the new configuration every time the problem condition changes dynamically. To generate dispatching rules for the ISBJSSP problem, we introduce a dynamic disjunctive graph formulation characterized by nodes and edges subjected to continuous deletions and additions. This formulation enables the training of an adaptive scheduler utilizing graph neural networks and reinforcement learning. Furthermore, a simulator is developed to simulate interruption, swapping, and blocking in the ISBJSSP setting. By employing a set of reported benchmark instances, we conduct a detailed experimental study on ISBJSSP instances with a range of machine shutdown probabilities to show that the scheduling policies generated can outperform or are at least as competitive as existing dispatching rules with predetermined priority. This study shows that the ISBJSSP, which requires real-time adaptive solutions, can be scheduled efficiently with the proposed method when production interruptions occur with random machine shutdowns.
{"title":"GENERATING DISPATCHING RULES FOR THE INTERRUPTING SWAP-ALLOWED BLOCKING JOB SHOP PROBLEM USING GRAPH NEURAL NETWORK AND REINFORCEMENT LEARNING","authors":"Vivian Wong, Sang Hun Kim, Junyoung Park, Jinkyoo Park, Kincho Law","doi":"10.1115/1.4063652","DOIUrl":"https://doi.org/10.1115/1.4063652","url":null,"abstract":"Abstract The interrupting swap-allowed blocking job shop problem (ISBJSSP) is a complex scheduling problem that is able to model many manufacturing planning and logistics applications realistically by addressing both the lack of storage capacity and unforeseen production interruptions. Subjected to random disruptions due to machine malfunction or maintenance, industry production settings often choose to adopt dispatching rules to enable adaptive, real-time re-scheduling, rather than traditional methods that require costly re-computation on the new configuration every time the problem condition changes dynamically. To generate dispatching rules for the ISBJSSP problem, we introduce a dynamic disjunctive graph formulation characterized by nodes and edges subjected to continuous deletions and additions. This formulation enables the training of an adaptive scheduler utilizing graph neural networks and reinforcement learning. Furthermore, a simulator is developed to simulate interruption, swapping, and blocking in the ISBJSSP setting. By employing a set of reported benchmark instances, we conduct a detailed experimental study on ISBJSSP instances with a range of machine shutdown probabilities to show that the scheduling policies generated can outperform or are at least as competitive as existing dispatching rules with predetermined priority. This study shows that the ISBJSSP, which requires real-time adaptive solutions, can be scheduled efficiently with the proposed method when production interruptions occur with random machine shutdowns.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135666691","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Abstract The process parameters of Directed Energy Deposition (DED) have been widely studied including laser power, powder flow rate, and scanning speed. These parameters affect clad dimension and melt pool temperature, which are directly related to part quality. However, laser/powder profiles and their alignment have obtained less attention due to the cumbersome characterization process, although they can be directly associated with local energy density for melt pool formation. This study examines the impact of the alignment between the laser beam and powder flow distributions in DED on clad dimension and melt pool temperature. The laser beam and powder profiles are characterized by measuring their respective 2D Gaussian profiles for a given standoff distance. Aligned and misaligned laser-powder profiles are then used to build single-clad square geometries. It was found that a 500-µm offset between the centers of the laser and powder profiles causes up to a 20% change in both the width and the height of a single clad as well as an average temperature increase of 100 K. To understand the interaction between powder flow, energy flux, and local temperature, the local specific energy density distribution was plotted in 2D. These results suggest that laser-powder misalignment may significantly alter the thermal history and shape of deposited clads, possibly preventing DED-manufactured parts from meeting design properties and causing build failures.
{"title":"Effects of Laser-Powder Alignment on Clad Dimension and Melt Pool Temperature in Directed Energy Deposition","authors":"Jihoon Jeong, Samantha Webster, Rujing Zha, Jon-Erik Mogonye, Kornel Ehmann, Jian Cao","doi":"10.1115/1.4063390","DOIUrl":"https://doi.org/10.1115/1.4063390","url":null,"abstract":"Abstract The process parameters of Directed Energy Deposition (DED) have been widely studied including laser power, powder flow rate, and scanning speed. These parameters affect clad dimension and melt pool temperature, which are directly related to part quality. However, laser/powder profiles and their alignment have obtained less attention due to the cumbersome characterization process, although they can be directly associated with local energy density for melt pool formation. This study examines the impact of the alignment between the laser beam and powder flow distributions in DED on clad dimension and melt pool temperature. The laser beam and powder profiles are characterized by measuring their respective 2D Gaussian profiles for a given standoff distance. Aligned and misaligned laser-powder profiles are then used to build single-clad square geometries. It was found that a 500-µm offset between the centers of the laser and powder profiles causes up to a 20% change in both the width and the height of a single clad as well as an average temperature increase of 100 K. To understand the interaction between powder flow, energy flux, and local temperature, the local specific energy density distribution was plotted in 2D. These results suggest that laser-powder misalignment may significantly alter the thermal history and shape of deposited clads, possibly preventing DED-manufactured parts from meeting design properties and causing build failures.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135944775","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Guest Editorial 2023 Manufacturing Science and Engineering Conference Accepted Manuscript Binil Starly, Binil Starly 5999 S Backus Mall Mesa, AZ 85212 Email: binil.starly@asu.edu Search for other works by this author on: This Site PubMed Google Scholar Albert Shih Albert Shih Mech Engrg 2350 Hayward St 1029 Dow Ann Arbor, MI 48109-2125 Email: shiha@umich.edu Search for other works by this author on: This Site PubMed Google Scholar Author and Article Information Binil Starly 5999 S Backus Mall Mesa, AZ 85212 Albert Shih Mech Engrg 2350 Hayward St 1029 Dow Ann Arbor, MI 48109-2125 Email: shiha@umich.edu Email: binil.starly@asu.edu J. Manuf. Sci. Eng. 1-2 (2 pages) Paper No: MANU-23-1588 https://doi.org/10.1115/1.4063521 Published Online: September 27, 2023 Article history Received: September 22, 2023 Revised: September 23, 2023 Accepted: September 23, 2023 Published: September 27, 2023
客座编辑2023制造科学与工程会议接受手稿Binil Starly, Binil Starly 5999 S Backus Mall Mesa, AZ 85212电子邮件:binil.starly@asu.edu搜索作者的其他作品在:本网站PubMed谷歌学者Albert Shih Albert Shih Mech Engrg 2350 Hayward St 1029 Dow Ann Arbor, MI 48109-2125电子邮件:shiha@umich.edu搜索作者的其他作品在:该网站PubMed谷歌学者作者和文章信息Binil Starly 5999 S Backus Mall Mesa, AZ 85212 Albert Shih Mech Engrg 2350 Hayward St 1029 Dow Ann Arbor, MI 48109-2125 Email: shiha@umich.edu Email: binil.starly@asu.edu J. Manuf. Sci。论文编号:MANU-23-1588 https://doi.org/10.1115/1.4063521发表时间:2023年9月27日收稿时间:2023年9月22日修稿时间:2023年9月23日收稿时间:2023年9月23日发表时间:2023年9月27日
{"title":"2023 Manufacturing Science and Engineering Conference","authors":"Binil Starly, Albert Shih","doi":"10.1115/1.4063521","DOIUrl":"https://doi.org/10.1115/1.4063521","url":null,"abstract":"Guest Editorial 2023 Manufacturing Science and Engineering Conference Accepted Manuscript Binil Starly, Binil Starly 5999 S Backus Mall Mesa, AZ 85212 Email: binil.starly@asu.edu Search for other works by this author on: This Site PubMed Google Scholar Albert Shih Albert Shih Mech Engrg 2350 Hayward St 1029 Dow Ann Arbor, MI 48109-2125 Email: shiha@umich.edu Search for other works by this author on: This Site PubMed Google Scholar Author and Article Information Binil Starly 5999 S Backus Mall Mesa, AZ 85212 Albert Shih Mech Engrg 2350 Hayward St 1029 Dow Ann Arbor, MI 48109-2125 Email: shiha@umich.edu Email: binil.starly@asu.edu J. Manuf. Sci. Eng. 1-2 (2 pages) Paper No: MANU-23-1588 https://doi.org/10.1115/1.4063521 Published Online: September 27, 2023 Article history Received: September 22, 2023 Revised: September 23, 2023 Accepted: September 23, 2023 Published: September 27, 2023","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135945123","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Abstract A significant challenge in human–robot collaboration (HRC) is coordinating robot and human motions. Discoordination can lead to production delays and human discomfort. Prior works seek coordination by planning robot paths that consider humans or their anticipated occupancy as static obstacles, making them nearsighted and prone to entrapment by human motion. This work presents the spatio-temporal avoidance of predictions-prediction and planning framework (STAP-PPF) to improve robot–human coordination in HRC. STAP-PPF predicts multi-step human motion sequences based on the locations of objects the human manipulates. STAP-PPF then proactively determines time-optimal robot paths considering predicted human motion and robot speed restrictions anticipated according to the ISO15066 speed and separation monitoring (SSM) mode. When executing robot paths, STAP-PPF continuously updates human motion predictions. In real-time, STAP-PPF warps the robot’s path to account for continuously updated human motion predictions and updated SSM effects to mitigate delays and human discomfort. Results show the STAP-PPF generates robot trajectories of shorter duration. STAP-PPF robot trajectories also adapted better to real-time human motion deviation. STAP-PPF robot trajectories also maintain greater robot/human separation throughout tasks requiring close human–robot interaction. Tests with an assembly sequence demonstrate STAP-PPF’s ability to predict multi-step human tasks and plan robot motions for the sequence. STAP-PPF also most accurately estimates robot trajectory durations, within 30% of actual, which can be used to adapt the robot sequencing to minimize disruption.
{"title":"A Spatio-Temporal Prediction and Planning Framework for Proactive Human-Robot Collaboration","authors":"Jared Flowers, Gloria Wiens","doi":"10.1115/1.4063502","DOIUrl":"https://doi.org/10.1115/1.4063502","url":null,"abstract":"Abstract A significant challenge in human–robot collaboration (HRC) is coordinating robot and human motions. Discoordination can lead to production delays and human discomfort. Prior works seek coordination by planning robot paths that consider humans or their anticipated occupancy as static obstacles, making them nearsighted and prone to entrapment by human motion. This work presents the spatio-temporal avoidance of predictions-prediction and planning framework (STAP-PPF) to improve robot–human coordination in HRC. STAP-PPF predicts multi-step human motion sequences based on the locations of objects the human manipulates. STAP-PPF then proactively determines time-optimal robot paths considering predicted human motion and robot speed restrictions anticipated according to the ISO15066 speed and separation monitoring (SSM) mode. When executing robot paths, STAP-PPF continuously updates human motion predictions. In real-time, STAP-PPF warps the robot’s path to account for continuously updated human motion predictions and updated SSM effects to mitigate delays and human discomfort. Results show the STAP-PPF generates robot trajectories of shorter duration. STAP-PPF robot trajectories also adapted better to real-time human motion deviation. STAP-PPF robot trajectories also maintain greater robot/human separation throughout tasks requiring close human–robot interaction. Tests with an assembly sequence demonstrate STAP-PPF’s ability to predict multi-step human tasks and plan robot motions for the sequence. STAP-PPF also most accurately estimates robot trajectory durations, within 30% of actual, which can be used to adapt the robot sequencing to minimize disruption.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135944282","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Taekwang Ha, Torgeir Welo, Geir Ringen, Jyhwen Wang
Abstract Springback is one of the factors that causes decreased product quality in metal forming. Advanced 2D and 3D stretch bending process can be used to manufacture a complex geometry a profile with springback reduction. For a non-linear springback problem, an artificial neural network (ANN) is an attractive data-driven approach to achieving springback prediction and control. The main objective of the present work is to control springback and improve geometrical quality with an ANN in 2D and 3D stretch bending. In general, an ANN is trained with collected data sets from a large number of experiments, causing expensive costs and time-consuming work. In the present work, the training data sets for the proposed ANN are obtained from both experiments and an analytical springback model. As the analytical model can adopt different bending angles, material properties, and geometries, supplementary data by the analytical model significantly reduced the number of experiments needed for ANN training. Contrary to the typical springback predictions, the proposed ANN synthesizes the machine settings based on the desired dimensions as the inputs. It is shown that springback can be controlled by specifying the bend angles provided by the ANN prediction. The proposed ANN method was validated in 2D and 3D stretch bending, and its prediction and control performance is favorably compared to an ANN trained with only experimental data sets.
{"title":"Smart Control of Springback in Stretch Bending of a Rectangular Tube by an Artificial Neural Network","authors":"Taekwang Ha, Torgeir Welo, Geir Ringen, Jyhwen Wang","doi":"10.1115/1.4063737","DOIUrl":"https://doi.org/10.1115/1.4063737","url":null,"abstract":"Abstract Springback is one of the factors that causes decreased product quality in metal forming. Advanced 2D and 3D stretch bending process can be used to manufacture a complex geometry a profile with springback reduction. For a non-linear springback problem, an artificial neural network (ANN) is an attractive data-driven approach to achieving springback prediction and control. The main objective of the present work is to control springback and improve geometrical quality with an ANN in 2D and 3D stretch bending. In general, an ANN is trained with collected data sets from a large number of experiments, causing expensive costs and time-consuming work. In the present work, the training data sets for the proposed ANN are obtained from both experiments and an analytical springback model. As the analytical model can adopt different bending angles, material properties, and geometries, supplementary data by the analytical model significantly reduced the number of experiments needed for ANN training. Contrary to the typical springback predictions, the proposed ANN synthesizes the machine settings based on the desired dimensions as the inputs. It is shown that springback can be controlled by specifying the bend angles provided by the ANN prediction. The proposed ANN method was validated in 2D and 3D stretch bending, and its prediction and control performance is favorably compared to an ANN trained with only experimental data sets.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136210186","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Anna Komodromos, Joshua Grodotzki, Felix Kolpak, A. Erman Tekkaya
Abstract By Directed Energy Deposition (DED) a flexible design of cooling channels in forming tools, e.g. hot stamping, with a variety of sizes and a high positioning flexibility compared to machining processes is possible. The subsequent ball burnishing of the tool surfaces in combination with a variation of the DED process parameters enables a control of the tool surface properties and the friction behavior. Parameters such as the ball burnishing pressure or the path overlapping in the DED process are investigated to quantify their effects on roughness, hardness, friction, residual stresses and heat transfer coefficient of generic tool surfaces. The friction coefficient at elevated temperatures depends strongly on the surface roughness of the tool steel surfaces generated by DED and ball burnishing. The latter process improves the surface integrity: the roughness peaks are leveled by up to 75 %, the hardness and the residual stresses are enhanced by up to 20 % and 70 %, respectively. However, the roughness of the tool surfaces is determined mainly by the path overlapping of the welded beads in the DED process. Despite the higher surface roughness, the heat transfer coefficient is in the range of conventionally manufactured tool surfaces of up to 2,700 W/m2K for contact pressures up to 40 MPa. First hot stamping experiments demonstrate that the tools manufactured by the novel process combination are able to manufacture 22MnB5 hat profiles with an increased and more homogenous hardness as well as more homogeneous thickness distribution compared to conventionally manufactured tools.
{"title":"Characterization of Tool Surface Properties Generated by Directed Energy Deposition and Subsequent Ball Burnishing","authors":"Anna Komodromos, Joshua Grodotzki, Felix Kolpak, A. Erman Tekkaya","doi":"10.1115/1.4063736","DOIUrl":"https://doi.org/10.1115/1.4063736","url":null,"abstract":"Abstract By Directed Energy Deposition (DED) a flexible design of cooling channels in forming tools, e.g. hot stamping, with a variety of sizes and a high positioning flexibility compared to machining processes is possible. The subsequent ball burnishing of the tool surfaces in combination with a variation of the DED process parameters enables a control of the tool surface properties and the friction behavior. Parameters such as the ball burnishing pressure or the path overlapping in the DED process are investigated to quantify their effects on roughness, hardness, friction, residual stresses and heat transfer coefficient of generic tool surfaces. The friction coefficient at elevated temperatures depends strongly on the surface roughness of the tool steel surfaces generated by DED and ball burnishing. The latter process improves the surface integrity: the roughness peaks are leveled by up to 75 %, the hardness and the residual stresses are enhanced by up to 20 % and 70 %, respectively. However, the roughness of the tool surfaces is determined mainly by the path overlapping of the welded beads in the DED process. Despite the higher surface roughness, the heat transfer coefficient is in the range of conventionally manufactured tool surfaces of up to 2,700 W/m2K for contact pressures up to 40 MPa. First hot stamping experiments demonstrate that the tools manufactured by the novel process combination are able to manufacture 22MnB5 hat profiles with an increased and more homogenous hardness as well as more homogeneous thickness distribution compared to conventionally manufactured tools.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136209942","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Abstract Selecting suitable cutting conditions is crucial in maintaining chatter stability and achieving acceptable surface quality. However, the selection of a constant set of cutting parameters is not feasible due to the time-varying dynamics of highly flexible thin-walled blades. This paper presents an optimal selection of tool orientation and spindle speed along the tool path as the metal is removed during the ball end milling of blades. The effects of tool orientation and speed on the mechanics and dynamics of the ball-end milling process are formulated. Test case simulations are used to demonstrate the impact of tool orientation and speed on chatter stability and forced vibrations. The proposed algorithm identifies the optimal spindle speed and tool orientation by continuously updating the workpiece dynamics as a function of time and tool position to achieve improved stability and surface quality. Stability simulations are conducted to assess the optimization approach's performance, and the results are compared with experiments by machining a series of thin-walled twisted fan blades.
{"title":"Chatter Avoidance by Spindle Speed and Orientation Planning in Five-Axis Ball-End Milling of Thin-Walled Blades","authors":"Behnam Karimi, Yusuf Altintas","doi":"10.1115/1.4063654","DOIUrl":"https://doi.org/10.1115/1.4063654","url":null,"abstract":"Abstract Selecting suitable cutting conditions is crucial in maintaining chatter stability and achieving acceptable surface quality. However, the selection of a constant set of cutting parameters is not feasible due to the time-varying dynamics of highly flexible thin-walled blades. This paper presents an optimal selection of tool orientation and spindle speed along the tool path as the metal is removed during the ball end milling of blades. The effects of tool orientation and speed on the mechanics and dynamics of the ball-end milling process are formulated. Test case simulations are used to demonstrate the impact of tool orientation and speed on chatter stability and forced vibrations. The proposed algorithm identifies the optimal spindle speed and tool orientation by continuously updating the workpiece dynamics as a function of time and tool position to achieve improved stability and surface quality. Stability simulations are conducted to assess the optimization approach's performance, and the results are compared with experiments by machining a series of thin-walled twisted fan blades.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135590871","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Hemant Agiwal, Hwasung Yeom, Kumar Sridharan, Shiva Rudraraju, Frank E. Pfefferkorn
Abstract The ‘radius of contact’ or the ‘real-rotational contact plane’, has been increasingly mentioned terminology in friction surfacing. However, the fundamental understanding of the flow dynamics behind this phenomenon is still very limited. The goal of this study was to understand the influence of spindle speed and consumable rod diameter on the flow dynamics and radius of contact during friction surfacing of 304L stainless steel over a substrate of the same material. Friction surfacing was performed using consumable rods with diameters of 4.76 mm, 9.52 mm, and 12.7 mm while using spindle speeds from 1,500 RPM to 20,000 RPM. The impact of spindle speed on deposition morphology, including the radius of contact, was studied. The radius of contact was calculated empirically and was found to be inversely proportional to the tangential velocity of the rod. The coupling between flow stresses and localized forces is hypothesized to be the key factor behind the variation of the radius of contact with processing conditions.
{"title":"Radius of Contact During Friction Surfacing of Stainless Steel 304L: Effect of Spindle Speed and Rod Diameter","authors":"Hemant Agiwal, Hwasung Yeom, Kumar Sridharan, Shiva Rudraraju, Frank E. Pfefferkorn","doi":"10.1115/1.4063653","DOIUrl":"https://doi.org/10.1115/1.4063653","url":null,"abstract":"Abstract The ‘radius of contact’ or the ‘real-rotational contact plane’, has been increasingly mentioned terminology in friction surfacing. However, the fundamental understanding of the flow dynamics behind this phenomenon is still very limited. The goal of this study was to understand the influence of spindle speed and consumable rod diameter on the flow dynamics and radius of contact during friction surfacing of 304L stainless steel over a substrate of the same material. Friction surfacing was performed using consumable rods with diameters of 4.76 mm, 9.52 mm, and 12.7 mm while using spindle speeds from 1,500 RPM to 20,000 RPM. The impact of spindle speed on deposition morphology, including the radius of contact, was studied. The radius of contact was calculated empirically and was found to be inversely proportional to the tangential velocity of the rod. The coupling between flow stresses and localized forces is hypothesized to be the key factor behind the variation of the radius of contact with processing conditions.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135549270","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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