D. Görick, A. Schuster, L. Larsen, Jonas Welsch, Tobias Karrasch, M. Kupke
Thermoplastic composites (TCs) enjoy high popularity in the field of engineering. Due to this popularity, there is a growing need to assemble this material with the help of fast and efficient joining processes. One joining process, which has seen increased use, is the process of ultrasonic welding. To make reliable statements about the quality of the joined material, some kind of quality assurance has to be made. In terms of ultrasonic spot welding, there are already some documented approaches for observing or predicting the joining quality, but some of these most promising parameters for quality assurance are difficult to measure in the process of continuous ultrasonic welding. This is why new parameters are investigated for their potential to improve the prediction of ultrasonic-welded TCs’ quality. Thermography and sound emission data have been found to have a correlation with the produced weld quality and are fed into different machine learning algorithms. Despite the relatively small dataset, trained algorithms reach binary classification rates of over 90%, indicating that the newly discovered parameters show the potential to improve the quality assurance of ultrasonic-welded TCs in the future. This improvement may enable the establishment of the ultrasonic welding of TCs in manufacturing.
{"title":"New Input Factors for Machine Learning Approaches to Predict the Weld Quality of Ultrasonically Welded Thermoplastic Composite Materials","authors":"D. Görick, A. Schuster, L. Larsen, Jonas Welsch, Tobias Karrasch, M. Kupke","doi":"10.3390/jmmp7050154","DOIUrl":"https://doi.org/10.3390/jmmp7050154","url":null,"abstract":"Thermoplastic composites (TCs) enjoy high popularity in the field of engineering. Due to this popularity, there is a growing need to assemble this material with the help of fast and efficient joining processes. One joining process, which has seen increased use, is the process of ultrasonic welding. To make reliable statements about the quality of the joined material, some kind of quality assurance has to be made. In terms of ultrasonic spot welding, there are already some documented approaches for observing or predicting the joining quality, but some of these most promising parameters for quality assurance are difficult to measure in the process of continuous ultrasonic welding. This is why new parameters are investigated for their potential to improve the prediction of ultrasonic-welded TCs’ quality. Thermography and sound emission data have been found to have a correlation with the produced weld quality and are fed into different machine learning algorithms. Despite the relatively small dataset, trained algorithms reach binary classification rates of over 90%, indicating that the newly discovered parameters show the potential to improve the quality assurance of ultrasonic-welded TCs in the future. This improvement may enable the establishment of the ultrasonic welding of TCs in manufacturing.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":" ","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-08-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44426907","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This work presents a cyber-physical drilling machine that incorporates technologies discovered in the fourth industrial revolution. The machine is designed to realize its state by detecting whether it hits or breaks through the workpiece, without the need for additional sensors apart from the position sensor. Such self-recognition enables the machine to adapt and shift the controllers that handle position, velocity, and force, based on the workpiece and the drilling environment. In the experiment, the machine can detect and switch controls that follow the drilling events (HIT and BREAKHTROUGH) within 0.1 and 0.5 s, respectively. The machine’s high visibility design is beneficial for classification of the workpiece material. By using a support-vector-machine (SVM) on thrust force and feed rate, the authors are seen to achieve 92.86% accuracy for classification of material, such as medium-density fiberboard (MDF), acrylic, and glass.
{"title":"Innovative Smart Drilling with Critical Event Detection and Material Classification","authors":"Kantawatchr Chaiprabha, R. Chanchareon","doi":"10.3390/jmmp7050155","DOIUrl":"https://doi.org/10.3390/jmmp7050155","url":null,"abstract":"This work presents a cyber-physical drilling machine that incorporates technologies discovered in the fourth industrial revolution. The machine is designed to realize its state by detecting whether it hits or breaks through the workpiece, without the need for additional sensors apart from the position sensor. Such self-recognition enables the machine to adapt and shift the controllers that handle position, velocity, and force, based on the workpiece and the drilling environment. In the experiment, the machine can detect and switch controls that follow the drilling events (HIT and BREAKHTROUGH) within 0.1 and 0.5 s, respectively. The machine’s high visibility design is beneficial for classification of the workpiece material. By using a support-vector-machine (SVM) on thrust force and feed rate, the authors are seen to achieve 92.86% accuracy for classification of material, such as medium-density fiberboard (MDF), acrylic, and glass.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":" ","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-08-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46374747","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Y. Suchikova, S. Kovachov, I. Bohdanov, Anar A. Abdikadirova, I. Kenzhina, Anatoli I. Popov
This work presents a novel, cost-effective method for synthesizing AlxGa1−xAs nanowhiskers on a GaAs surface by electrochemical deposition. The process begins with structuring the GaAs surface by electrochemical etching, forming a branched nanowhisker system. Despite the close resemblance of the crystal lattices of AlAs, GaAs, and AlxGa1−xAs, our study highlights the formation of nanowhiskers instead of layer-by-layer film growth. X-ray diffraction analysis and photoluminescence spectrum evaluations confirm the synthesized structure’s crystallinity, uniformity, and bandgap characteristics. The unique morphology of the nanowhiskers offers promising implications for solar cell applications because of the increased light absorption potential and reduced surface recombination energy losses. We conclude by emphasizing the need for further studies on the growth mechanisms of AlxGa1−xAs nanowhiskers, adjustments of the “x” parameter during electrochemical deposition, and detailed light absorption properties of the formed compounds. This research contributes to the field of wideband materials, particularly for solar energy applications, highlighting the potential of electrochemical deposition as a flexible and economical fabrication method.
{"title":"Electrochemical Growth and Structural Study of the AlxGa1−xAs Nanowhisker Layer on the GaAs Surface","authors":"Y. Suchikova, S. Kovachov, I. Bohdanov, Anar A. Abdikadirova, I. Kenzhina, Anatoli I. Popov","doi":"10.3390/jmmp7050153","DOIUrl":"https://doi.org/10.3390/jmmp7050153","url":null,"abstract":"This work presents a novel, cost-effective method for synthesizing AlxGa1−xAs nanowhiskers on a GaAs surface by electrochemical deposition. The process begins with structuring the GaAs surface by electrochemical etching, forming a branched nanowhisker system. Despite the close resemblance of the crystal lattices of AlAs, GaAs, and AlxGa1−xAs, our study highlights the formation of nanowhiskers instead of layer-by-layer film growth. X-ray diffraction analysis and photoluminescence spectrum evaluations confirm the synthesized structure’s crystallinity, uniformity, and bandgap characteristics. The unique morphology of the nanowhiskers offers promising implications for solar cell applications because of the increased light absorption potential and reduced surface recombination energy losses. We conclude by emphasizing the need for further studies on the growth mechanisms of AlxGa1−xAs nanowhiskers, adjustments of the “x” parameter during electrochemical deposition, and detailed light absorption properties of the formed compounds. This research contributes to the field of wideband materials, particularly for solar energy applications, highlighting the potential of electrochemical deposition as a flexible and economical fabrication method.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":" ","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-08-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42786425","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Carsten Schmidt, Adrian Morlock, Rainer Griesbaum, J. Sehrt, F. Finsterwalder
Users of material extrusion printers are faced with a wide range of prices. It is unknown which printer price can achieve the required part quality. However, the price and the resulting quality of a printer are decisive factors for the process, especially at small- and medium-sized companies. This study investigated the correlation between the printer price and part quality based on dimensional accuracy, surface quality, strength, and visual appearance. In this paper, 14 printers with different prices were examined. The relationship of printer price and part defects, elongation at break, and the accuracy of roundings could be identified (the regressions achieved a p-value under 0.5 and an R2 over 0.4). A relationship with surface roughness, tensile strength, or other dimensional accuracy characteristics could not be found (the regressions achieved an R2 under 0.4 or anomalies could be detected in the regression analysis). In the performed investigations, more-expensive printers were not necessarily associated with an improvement in these quality characteristics. No relationship between the printer price and the standard deviation, e.g., less variation in part quality, could be identified. This paper provides valuable insights into the relationship of part quality and printer price. The performed research improved upon the existing literature in terms of the number of investigated printers, the observed price range, and the number of tested quality characteristics. The results and approach of this paper will help users select an appropriate printer, and the findings can be used in the sourcing and technology selection phases.
{"title":"Investigation of Part Quality Achieved by Material Extrusion Printers in Relation to Their Price","authors":"Carsten Schmidt, Adrian Morlock, Rainer Griesbaum, J. Sehrt, F. Finsterwalder","doi":"10.3390/jmmp7040152","DOIUrl":"https://doi.org/10.3390/jmmp7040152","url":null,"abstract":"Users of material extrusion printers are faced with a wide range of prices. It is unknown which printer price can achieve the required part quality. However, the price and the resulting quality of a printer are decisive factors for the process, especially at small- and medium-sized companies. This study investigated the correlation between the printer price and part quality based on dimensional accuracy, surface quality, strength, and visual appearance. In this paper, 14 printers with different prices were examined. The relationship of printer price and part defects, elongation at break, and the accuracy of roundings could be identified (the regressions achieved a p-value under 0.5 and an R2 over 0.4). A relationship with surface roughness, tensile strength, or other dimensional accuracy characteristics could not be found (the regressions achieved an R2 under 0.4 or anomalies could be detected in the regression analysis). In the performed investigations, more-expensive printers were not necessarily associated with an improvement in these quality characteristics. No relationship between the printer price and the standard deviation, e.g., less variation in part quality, could be identified. This paper provides valuable insights into the relationship of part quality and printer price. The performed research improved upon the existing literature in terms of the number of investigated printers, the observed price range, and the number of tested quality characteristics. The results and approach of this paper will help users select an appropriate printer, and the findings can be used in the sourcing and technology selection phases.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":" ","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42421293","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
A. Zardoshtian, R. Esmaeilizadeh, M. Ansari, M. Keshavarz, H. Jahed, E. Toyserkani
Laser-directed energy deposition (LDED) is a promising technology for coating, repairing, and building near-net-shape 3D structures. However, the processing of copper alloys, specifically, has presented a significant challenge due to their low laser absorptivity at the 1060 nm laser wavelength and high thermal conductivity. This study undertook a methodical examination by employing a 2 kW disk laser, operating at a wavelength of 1064 nm, and a coaxial nozzle head to comprehensively examine the processability of the highly conductive CuCrZr alloy for expanding the range of materials that can be successfully processed using LDED. The investigation focuses not only on optimizing the input process parameters that are the laser power, scanning speed, powder feed rate, and overlap ratio, but also on planning the toolpath trajectory, as these factors were found to exert a substantial influence on processability, geometrical accuracy, and the occurrence of defects such as lack of fusion. The optimal toolpath trajectory discovered involved implementing a zigzag strategy combined with a 90° rotation of the scanning direction. Additionally, a start point rotation was considered between each layer to even out the deposition of the layers. Moreover, a contour with a radial path at the corners was introduced to enhance the overall trajectory. Based on the hierarchal experimental study, the appropriate ranges for the key process parameters that leads to 99.99% relative density have been identified. They were found to be from 1100 up to 2000 W for the laser power (P), and from 0.003 up to 0.016 g/mm for the amount of powder that is fed to the melt pool distance (F/V). Regarding the influence of process parameters on the microstructure of the samples with equal deposition height, it was observed that varying combinations of process parameters within the optimal processing window resulted in variations in grain size ranging from 105 to 215 µm.
{"title":"On the Processability and Microstructural Evolution of CuCrZr in Multilayer Laser-Directed Energy Deposition Additive Manufacturing via Statistical and Experimental Methods","authors":"A. Zardoshtian, R. Esmaeilizadeh, M. Ansari, M. Keshavarz, H. Jahed, E. Toyserkani","doi":"10.3390/jmmp7040151","DOIUrl":"https://doi.org/10.3390/jmmp7040151","url":null,"abstract":"Laser-directed energy deposition (LDED) is a promising technology for coating, repairing, and building near-net-shape 3D structures. However, the processing of copper alloys, specifically, has presented a significant challenge due to their low laser absorptivity at the 1060 nm laser wavelength and high thermal conductivity. This study undertook a methodical examination by employing a 2 kW disk laser, operating at a wavelength of 1064 nm, and a coaxial nozzle head to comprehensively examine the processability of the highly conductive CuCrZr alloy for expanding the range of materials that can be successfully processed using LDED. The investigation focuses not only on optimizing the input process parameters that are the laser power, scanning speed, powder feed rate, and overlap ratio, but also on planning the toolpath trajectory, as these factors were found to exert a substantial influence on processability, geometrical accuracy, and the occurrence of defects such as lack of fusion. The optimal toolpath trajectory discovered involved implementing a zigzag strategy combined with a 90° rotation of the scanning direction. Additionally, a start point rotation was considered between each layer to even out the deposition of the layers. Moreover, a contour with a radial path at the corners was introduced to enhance the overall trajectory. Based on the hierarchal experimental study, the appropriate ranges for the key process parameters that leads to 99.99% relative density have been identified. They were found to be from 1100 up to 2000 W for the laser power (P), and from 0.003 up to 0.016 g/mm for the amount of powder that is fed to the melt pool distance (F/V). Regarding the influence of process parameters on the microstructure of the samples with equal deposition height, it was observed that varying combinations of process parameters within the optimal processing window resulted in variations in grain size ranging from 105 to 215 µm.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":" ","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-08-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43192401","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
J. Pereira, David Aguilar, Iosu Tellería, Raúl Gómez, M. San Sebastian
In this work, a semi-continuous functionally graded material (FGM) between an austenitic and a super duplex stainless steel was obtained. These materials are of great interest for the chemical, offshore, and oil and gas sectors since the austenitic stainless steel type 316L is common (and not so expensive) and super duplex stainless steels have better mechanical and corrosion resistance but are more expensive and complex in their microstructural phases formation and the obtention of the balance between their main phases. Using directed energy deposition, it was possible to efficiently combine two powders of different chemical compositions by automated mixing prior to their delivery into the nozzle, coaxially to the laser beam for melting. A dense material via additive manufacturing was obtained, with minimum defectology and with a semi-continuous and controlled chemical compositional gradient in the manufactured part. The evolution of ferrite formation has been verified and the phase fraction measured. The resulting microstructure, austenite/ferrite ratio, and hardness variations were evaluated, starting from 100% austenitic stainless-steel composition and with variants of 5% in wt.% until achieving 100% of super duplex steel at the end of the part. Finally, the correlation between the increase in hardness of the FGM with the increase in the ferrite phase area fraction was verified.
{"title":"Semi-Continuous Functionally Graded Material Austenitic to Super Duplex Stainless Steel Obtained by Laser-Based Directed Energy Deposition","authors":"J. Pereira, David Aguilar, Iosu Tellería, Raúl Gómez, M. San Sebastian","doi":"10.3390/jmmp7040150","DOIUrl":"https://doi.org/10.3390/jmmp7040150","url":null,"abstract":"In this work, a semi-continuous functionally graded material (FGM) between an austenitic and a super duplex stainless steel was obtained. These materials are of great interest for the chemical, offshore, and oil and gas sectors since the austenitic stainless steel type 316L is common (and not so expensive) and super duplex stainless steels have better mechanical and corrosion resistance but are more expensive and complex in their microstructural phases formation and the obtention of the balance between their main phases. Using directed energy deposition, it was possible to efficiently combine two powders of different chemical compositions by automated mixing prior to their delivery into the nozzle, coaxially to the laser beam for melting. A dense material via additive manufacturing was obtained, with minimum defectology and with a semi-continuous and controlled chemical compositional gradient in the manufactured part. The evolution of ferrite formation has been verified and the phase fraction measured. The resulting microstructure, austenite/ferrite ratio, and hardness variations were evaluated, starting from 100% austenitic stainless-steel composition and with variants of 5% in wt.% until achieving 100% of super duplex steel at the end of the part. Finally, the correlation between the increase in hardness of the FGM with the increase in the ferrite phase area fraction was verified.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":" ","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-08-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48089472","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
While Inconel 718 is a widely used engineering material in industrial fields such as the aerospace and automotive fields, the machined surface integrity has a significant effect on the performance of its components and parts. In this work, the laser-assisted micro-milling process of Inconel 718 is investigated using a combination of experiments and finite element simulations. Firstly, an experimental platform of laser-assisted milling is built, and a three-dimensional thermal–mechanical coupled finite element model of laser-assisted milling of Inconel 718 is then established. Secondly, laser-assisted milling experiments and finite element simulations are conducted to investigate the impact of laser assistance on cutting force, chip morphology, tool wear and surface topography of Inconel 718 under a milling process. The results indicate that laser-assisted milling results in a moderate reduction in cutting forces while enhancing surface integrity and chip continuity, as compared with ordinary milling. Thirdly, orthogonal experiments of laser-assisted milling of Inconel 718 are conducted to discover the optimal processing parameters, including spindle speed, feed per tooth, milling depth and laser parameters. Finally, single-factor experiments are conducted to investigate the effect of laser power on cutting force, chip morphology, tool wear, groove burr and surface roughness in the laser-assisted milling of Inconel 718. And, a minimal surface roughness Sa of 137 nm for Inconel 718 accompanied by minimal tool wear is experimentally obtained via laser-assisted milling. These findings highlight the effectiveness of applying laser assistance in enhancing the machinability of difficult-to-machine materials for achieving desirable machined surface integrity.
{"title":"Investigation of Laser-Assisted Micro-Milling Process of Inconel 718","authors":"Haijun Zhang, Fei Chen, Zengqiang Li, Wangjie Hu, T. Sun, Junjie Zhang","doi":"10.3390/jmmp7040149","DOIUrl":"https://doi.org/10.3390/jmmp7040149","url":null,"abstract":"While Inconel 718 is a widely used engineering material in industrial fields such as the aerospace and automotive fields, the machined surface integrity has a significant effect on the performance of its components and parts. In this work, the laser-assisted micro-milling process of Inconel 718 is investigated using a combination of experiments and finite element simulations. Firstly, an experimental platform of laser-assisted milling is built, and a three-dimensional thermal–mechanical coupled finite element model of laser-assisted milling of Inconel 718 is then established. Secondly, laser-assisted milling experiments and finite element simulations are conducted to investigate the impact of laser assistance on cutting force, chip morphology, tool wear and surface topography of Inconel 718 under a milling process. The results indicate that laser-assisted milling results in a moderate reduction in cutting forces while enhancing surface integrity and chip continuity, as compared with ordinary milling. Thirdly, orthogonal experiments of laser-assisted milling of Inconel 718 are conducted to discover the optimal processing parameters, including spindle speed, feed per tooth, milling depth and laser parameters. Finally, single-factor experiments are conducted to investigate the effect of laser power on cutting force, chip morphology, tool wear, groove burr and surface roughness in the laser-assisted milling of Inconel 718. And, a minimal surface roughness Sa of 137 nm for Inconel 718 accompanied by minimal tool wear is experimentally obtained via laser-assisted milling. These findings highlight the effectiveness of applying laser assistance in enhancing the machinability of difficult-to-machine materials for achieving desirable machined surface integrity.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":" ","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-08-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49588526","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
W. El-Garaihy, A. I. Alateyah, Mahmoud Shaban, M. F. Alsharekh, F. Alsunaydih, Samar El-Sanabary, H. Kouta, Yasmine El-Taybany, H. Salem
This work investigates the efficacy of high-pressure torsion (HPT), as a severe plastic deformation mechanism for processing plain and silicon-carbide-reinforced AA6061, with the broader objective of using the technique for improving the properties of lightweight materials for a range of objectives. The interactions between input variables, such as the pressure and equivalent strain (εeq) applied during HPT processing, and the presence of SiCp and response variables, like the relative density, grain refinement, homogeneity of the structure, and the mechanical properties of the AA6061 aluminum matrix, were investigated. Hot compaction (HC) of the mixed powders followed by HPT were employed to produce AA6061 discs with and without 15% SiCp. The experimental findings were then analyzed statistically using the response surface methodology (RSM) and a machine learning (ML) approach to predict the output variables and to optimize the input parameters. The optimum combination of HPT process parameters was confirmed by the genetic algorithm (GA) and ML approaches. Furthermore, the constructed ML and RSM models were validated experimentally by HPT processing the same material under new conditions not fed into the models and comparing the experimental results to those predicted by the model. From the ML and RSM models, it was found that processing the AA6061/SiCp composite HPT via four revolutions at 3 GPa produced the highest mechanical properties coupled with significant grain refinement compared to the HC condition. ML analysis revealed that the equivalent strain induced by the number of revolutions was the most effective parameter for grain refinement, whereas the presence of SiCp played the highest role in improving both the hardness values and the compressive strength of the AA6061 matrices.
{"title":"A Comparative Study of a Machine Learning Approach and Response Surface Methodology for Optimizing the HPT Processing Parameters of AA6061/SiCp Composites","authors":"W. El-Garaihy, A. I. Alateyah, Mahmoud Shaban, M. F. Alsharekh, F. Alsunaydih, Samar El-Sanabary, H. Kouta, Yasmine El-Taybany, H. Salem","doi":"10.3390/jmmp7040148","DOIUrl":"https://doi.org/10.3390/jmmp7040148","url":null,"abstract":"This work investigates the efficacy of high-pressure torsion (HPT), as a severe plastic deformation mechanism for processing plain and silicon-carbide-reinforced AA6061, with the broader objective of using the technique for improving the properties of lightweight materials for a range of objectives. The interactions between input variables, such as the pressure and equivalent strain (εeq) applied during HPT processing, and the presence of SiCp and response variables, like the relative density, grain refinement, homogeneity of the structure, and the mechanical properties of the AA6061 aluminum matrix, were investigated. Hot compaction (HC) of the mixed powders followed by HPT were employed to produce AA6061 discs with and without 15% SiCp. The experimental findings were then analyzed statistically using the response surface methodology (RSM) and a machine learning (ML) approach to predict the output variables and to optimize the input parameters. The optimum combination of HPT process parameters was confirmed by the genetic algorithm (GA) and ML approaches. Furthermore, the constructed ML and RSM models were validated experimentally by HPT processing the same material under new conditions not fed into the models and comparing the experimental results to those predicted by the model. From the ML and RSM models, it was found that processing the AA6061/SiCp composite HPT via four revolutions at 3 GPa produced the highest mechanical properties coupled with significant grain refinement compared to the HC condition. ML analysis revealed that the equivalent strain induced by the number of revolutions was the most effective parameter for grain refinement, whereas the presence of SiCp played the highest role in improving both the hardness values and the compressive strength of the AA6061 matrices.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":" ","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-08-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46781968","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The demands on joining technology are constantly increasing due to the consistent lightweight construction and the associated increasing material mix. To meet these requirements, the adaptability of the joining processes must be improved to be able to process different material combinations and to react to challenges caused by deviations in the process chain. One example of a highly adaptable process due to the two-step process sequence is thermomechanical joining with Friction Spun Joint Connectors (FSJCs) that can be individually adapted to the joint. In this paper, the potentials of the adaption in the two-stage joining process with aluminium auxiliary joining elements are investigated. To this end, it is first investigated whether a thermomechanical forming process can be used to achieve a uniform and controlled manufacturing regarding the process variable of the temperature as well as the geometry of the FSJC. Based on the successful proof of the high and good repeatability in the FSJC manufacturing, possibilities, and potentials for the targeted influencing of the process and FSJC geometry are shown, based on an extensive variation of the process input variables (delivery condition and thus mechanical properties of the raw parts as well as the process parameters of rotational speed and feed rate). Here it can be shown that above all, the feed rate of the final forming process has the strongest influence on the process and thus also offers the strongest possibilities for influencing it.
{"title":"Investigations on the Influences of the Thermomechanical Manufacturing of Aluminium Auxiliary Joining Elements","authors":"T. Borgert, Maximilian Henke, W. Homberg","doi":"10.3390/jmmp7040147","DOIUrl":"https://doi.org/10.3390/jmmp7040147","url":null,"abstract":"The demands on joining technology are constantly increasing due to the consistent lightweight construction and the associated increasing material mix. To meet these requirements, the adaptability of the joining processes must be improved to be able to process different material combinations and to react to challenges caused by deviations in the process chain. One example of a highly adaptable process due to the two-step process sequence is thermomechanical joining with Friction Spun Joint Connectors (FSJCs) that can be individually adapted to the joint. In this paper, the potentials of the adaption in the two-stage joining process with aluminium auxiliary joining elements are investigated. To this end, it is first investigated whether a thermomechanical forming process can be used to achieve a uniform and controlled manufacturing regarding the process variable of the temperature as well as the geometry of the FSJC. Based on the successful proof of the high and good repeatability in the FSJC manufacturing, possibilities, and potentials for the targeted influencing of the process and FSJC geometry are shown, based on an extensive variation of the process input variables (delivery condition and thus mechanical properties of the raw parts as well as the process parameters of rotational speed and feed rate). Here it can be shown that above all, the feed rate of the final forming process has the strongest influence on the process and thus also offers the strongest possibilities for influencing it.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":" ","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-08-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42384866","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
A. Sagitov, K. Sherov, B. Mardonov, Yerzhan Akhmetov, Z. Ramazanova, S. Ainabekova, Gulerke Tattimbek, G. Tussupbekova, A. Esirkepov
This article presents the results of an experimental study on improving the durability of cup cutters through pre-processing. A review of existing methods of increasing the durability of metal-cutting tools is carried out. The conducted experiments and simulations confirmed the application of pre-processing to increase the durability of cup cutters and the hardening of the cutting part after pre-processing, which approves the formation of a secondary contact structure in the pre-processing process. Dependence for determining a period of the durability of cup cutters at various regimes of pre-processing is deduced.
{"title":"Experimental Study of Improving the Durability of a Cup Cutter by Pre-Processing","authors":"A. Sagitov, K. Sherov, B. Mardonov, Yerzhan Akhmetov, Z. Ramazanova, S. Ainabekova, Gulerke Tattimbek, G. Tussupbekova, A. Esirkepov","doi":"10.3390/jmmp7040146","DOIUrl":"https://doi.org/10.3390/jmmp7040146","url":null,"abstract":"This article presents the results of an experimental study on improving the durability of cup cutters through pre-processing. A review of existing methods of increasing the durability of metal-cutting tools is carried out. The conducted experiments and simulations confirmed the application of pre-processing to increase the durability of cup cutters and the hardening of the cutting part after pre-processing, which approves the formation of a secondary contact structure in the pre-processing process. Dependence for determining a period of the durability of cup cutters at various regimes of pre-processing is deduced.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":" ","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-08-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48277461","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
京公网安备 11010802042870号
京ICP备2023020795号-1
扫码关注我们
求助内容：
应助结果提醒方式：