Pub Date : 2024-07-26DOI: 10.1177/09544054241265154
Liang Deng
The primary concern for manufacturers related to press hardening is productivity, which can deteriorate owing to wear. Severe tribological behaviours, such as abrasive and adhesive wear, lead to blank rupture, surface scratches and shape deviation of the formed parts, increasing the cost and time required for maintenance. To understand the mechanism governing tribological behaviours during consecutive stamping strokes, this study proposes a finite element (FE) simulation of the interface between the blank and tool steel. The FE simulation involves measuring the surface topography in a real stamping tool to obtain local contact conditions. The effects of the nominal pressure and range of the friction coefficient on the local contact conditions were studied. A tribological test capable of accurately reproducing the press hardening conditions was conducted to validate FE simulation. The local contact conditions in terms of contact pressure, contact area and sliding distance were found to differ from the nominal values. The proposed FE simulation involving a rough surface explores the possible length scale of the surface topography, wherein the calculated parameters are likely the main factors affecting wear. Furthermore, the correlation between the test variables and local contact conditions can help optimise the process parameters and lubricity.
冲压淬火生产商最关心的问题是生产率，因为磨损会导致生产率下降。严重的摩擦行为，如磨料和粘合剂磨损，会导致坯料破裂、表面划伤和成型零件形状偏差，从而增加维护成本和时间。为了解连续冲压行程中摩擦学行为的机理，本研究提出对毛坯和工具钢之间的界面进行有限元（FE）模拟。有限元模拟包括测量真实冲压工具的表面形貌，以获得局部接触条件。研究了公称压力和摩擦系数范围对局部接触条件的影响。为了验证 FE 模拟，还进行了能够精确再现冲压硬化条件的摩擦学测试。结果发现，接触压力、接触面积和滑动距离等局部接触条件与标称值不同。所提出的涉及粗糙表面的有限元模拟探索了表面形貌的可能长度范围，其中计算出的参数可能是影响磨损的主要因素。此外，测试变量与局部接触条件之间的相关性有助于优化工艺参数和润滑性。
{"title":"Numerical study on local contact conditions on rough surface under press hardening","authors":"Liang Deng","doi":"10.1177/09544054241265154","DOIUrl":"https://doi.org/10.1177/09544054241265154","url":null,"abstract":"The primary concern for manufacturers related to press hardening is productivity, which can deteriorate owing to wear. Severe tribological behaviours, such as abrasive and adhesive wear, lead to blank rupture, surface scratches and shape deviation of the formed parts, increasing the cost and time required for maintenance. To understand the mechanism governing tribological behaviours during consecutive stamping strokes, this study proposes a finite element (FE) simulation of the interface between the blank and tool steel. The FE simulation involves measuring the surface topography in a real stamping tool to obtain local contact conditions. The effects of the nominal pressure and range of the friction coefficient on the local contact conditions were studied. A tribological test capable of accurately reproducing the press hardening conditions was conducted to validate FE simulation. The local contact conditions in terms of contact pressure, contact area and sliding distance were found to differ from the nominal values. The proposed FE simulation involving a rough surface explores the possible length scale of the surface topography, wherein the calculated parameters are likely the main factors affecting wear. Furthermore, the correlation between the test variables and local contact conditions can help optimise the process parameters and lubricity.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":1.9,"publicationDate":"2024-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141800490","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}
Pub Date : 2024-07-26DOI: 10.1177/09544054241260470
Meng Wang, Xin Shen, Yipeng Wu, Beibei Sun
A new metamaterial structure has been developed with ultra-low expansion characteristics, featuring a unidirectional thermal expansion coefficient of less than 1 × 10−7/°C. Metamaterial structure is a new type of composite material designed artificially, by combining material technology with mechanical design technology, to achieve properties that cannot be achieved by conventional materials. Using the metamaterial design method, two materials with a large difference in thermal expansion coefficient are selected to design and realize the negative expansion unit structure. Combining the designed negative expansion structure and the conventional structure with positive expansion, the ultra-low expansion characteristics are finally realized through the mutual compensation of the thermal deformation properties of the two. The ultra-low thermal expansion characteristics of the novel metamaterial structures are verified through material modeling and simulation analysis.
{"title":"Research on low-expansion metamaterial technique of four-leaf clover bionic structure","authors":"Meng Wang, Xin Shen, Yipeng Wu, Beibei Sun","doi":"10.1177/09544054241260470","DOIUrl":"https://doi.org/10.1177/09544054241260470","url":null,"abstract":"A new metamaterial structure has been developed with ultra-low expansion characteristics, featuring a unidirectional thermal expansion coefficient of less than 1 × 10−7/°C. Metamaterial structure is a new type of composite material designed artificially, by combining material technology with mechanical design technology, to achieve properties that cannot be achieved by conventional materials. Using the metamaterial design method, two materials with a large difference in thermal expansion coefficient are selected to design and realize the negative expansion unit structure. Combining the designed negative expansion structure and the conventional structure with positive expansion, the ultra-low expansion characteristics are finally realized through the mutual compensation of the thermal deformation properties of the two. The ultra-low thermal expansion characteristics of the novel metamaterial structures are verified through material modeling and simulation analysis.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":1.9,"publicationDate":"2024-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141800499","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}
Pub Date : 2024-07-25DOI: 10.1177/09544054241260082
Zhenchao Qi, Tao Zhong, Jie Yang, Fuzhen Yu, Chenxi Yao
The durability of bolted composite joints has long been a significant concern within the field. However, the specific influence of transverse vibration relaxation on bolted composite joints has not been extensively studied. This study aims to investigate the effects of transverse vibration relaxation on bolted composite joints. A series of transverse vibration experiments were conducted to investigate the effect of initial preload, displacement load, and lubrication position on bolt preload relaxation. Additionally, tensile tests were performed on composite joints after relaxation and without relaxation to evaluate mechanical properties quantitatively. A finite element model was established to reveal the mechanism of damage evolution. The results indicate that displacement load and thread lubrication have the most significant influence on bolt preload relaxation. The clamping force of the composite structure generated by the smaller preload force has a limited effect on damage suppression during the tensile process. The relaxation of bolt preload can be effectively reduced by increasing the initial preload properly. The tensile strength of composite laminated structures with 10%, 22%, and 32% relaxation (10.4 kN initial preload) decreased by 5%, 6%, and 11%, respectively. Transverse vibration relaxation affects the tensile strength of composite structures, which is caused by the decay of preload. In contrast, the damage to the hole wall of the connection domain caused by transverse vibration almost does not affect the bearing capacity of the composite joints. Overall, this research contributes to the understanding of bolted composite joints’ durability by uncovering the novel effects of transverse vibration relaxation and providing valuable insights for design and optimization strategies in composite joint applications.
{"title":"Effects of bolt preload relaxation on the mechanical performance of composite structures","authors":"Zhenchao Qi, Tao Zhong, Jie Yang, Fuzhen Yu, Chenxi Yao","doi":"10.1177/09544054241260082","DOIUrl":"https://doi.org/10.1177/09544054241260082","url":null,"abstract":"The durability of bolted composite joints has long been a significant concern within the field. However, the specific influence of transverse vibration relaxation on bolted composite joints has not been extensively studied. This study aims to investigate the effects of transverse vibration relaxation on bolted composite joints. A series of transverse vibration experiments were conducted to investigate the effect of initial preload, displacement load, and lubrication position on bolt preload relaxation. Additionally, tensile tests were performed on composite joints after relaxation and without relaxation to evaluate mechanical properties quantitatively. A finite element model was established to reveal the mechanism of damage evolution. The results indicate that displacement load and thread lubrication have the most significant influence on bolt preload relaxation. The clamping force of the composite structure generated by the smaller preload force has a limited effect on damage suppression during the tensile process. The relaxation of bolt preload can be effectively reduced by increasing the initial preload properly. The tensile strength of composite laminated structures with 10%, 22%, and 32% relaxation (10.4 kN initial preload) decreased by 5%, 6%, and 11%, respectively. Transverse vibration relaxation affects the tensile strength of composite structures, which is caused by the decay of preload. In contrast, the damage to the hole wall of the connection domain caused by transverse vibration almost does not affect the bearing capacity of the composite joints. Overall, this research contributes to the understanding of bolted composite joints’ durability by uncovering the novel effects of transverse vibration relaxation and providing valuable insights for design and optimization strategies in composite joint applications.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":1.9,"publicationDate":"2024-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141804370","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}
To resolve the issue of cooperative operation between large fixed wing Unmanned Aerial Vehicle (UAV) and civil aviation manned transport aircraft, preprocessing of large fixed wing UAV flight data that oriented to spatial dimension will be carried out to further complete the mathematical description and sort out the characteristics of the flight data of the digital twins, analyze the track protection zone of flight program recommended by International Civil Aviation Organization (ICAO) and systematic errors such as collision risks, then develop a flight conflict detection method applied to cooperative operation in joint airspace and draw certain quantitative conclusion. According to the simulation experiments and calculation results, it is shown that the use of the multi-element composite strategy (MCS) can achieve the flight conflict assessment of the joint airspace cooperative operation, and according to the assessment results combined with the implementation environment of the flight mission, it can be concluded that the density of the airspace is within the range of the systematic error standard stipulated by the ICAO, so as to complete the quantitative assessment of the safety risk of the cooperative operation and the planning scheme of the joint airspace Preliminary formulation, to provide support for the development of intelligent logistics.
{"title":"Flight conflict detection of large fixed-wing UAV in joint airspace","authors":"Xin Ma, Zixuan Li, Zhou Yang, Xikang Lu, Linxin Zheng","doi":"10.1177/09544054241256996","DOIUrl":"https://doi.org/10.1177/09544054241256996","url":null,"abstract":"To resolve the issue of cooperative operation between large fixed wing Unmanned Aerial Vehicle (UAV) and civil aviation manned transport aircraft, preprocessing of large fixed wing UAV flight data that oriented to spatial dimension will be carried out to further complete the mathematical description and sort out the characteristics of the flight data of the digital twins, analyze the track protection zone of flight program recommended by International Civil Aviation Organization (ICAO) and systematic errors such as collision risks, then develop a flight conflict detection method applied to cooperative operation in joint airspace and draw certain quantitative conclusion. According to the simulation experiments and calculation results, it is shown that the use of the multi-element composite strategy (MCS) can achieve the flight conflict assessment of the joint airspace cooperative operation, and according to the assessment results combined with the implementation environment of the flight mission, it can be concluded that the density of the airspace is within the range of the systematic error standard stipulated by the ICAO, so as to complete the quantitative assessment of the safety risk of the cooperative operation and the planning scheme of the joint airspace Preliminary formulation, to provide support for the development of intelligent logistics.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":1.9,"publicationDate":"2024-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141804457","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}
Pub Date : 2024-07-24DOI: 10.1177/09544054241260928
Cole Yorston, Cheng Chen, Jaime Camelio
Advancements in data-driven predictive maintenance have significantly improved digital twin applications for rotating machinery, offering robust solutions for smart manufacturing challenges. These improvements are crucial since equipment failures can cause extensive and costly disruptions to both maintenance schedules and operations. As precision and reliability are critical in production processes, undetected fluctuations in operating frequencies can swiftly escalate to complete part failure, leading to prolonged repairs and productivity loss. This study explores an integrated dataflow pipeline, specifically through Siemens’ MindSphere, to enable continuous predictive maintenance and enhance data acquisition and management. Particularly, conditions such as normal operation, mass balance, rotating imbalance, and mechanical looseness are classified using support vector machine (SVM), neural network (NN), and K-Nearest Neighbor (KNN) methods for the purpose of comparing results. Our results highlight the efficacy of ensemble techniques in collecting and diagnosing vibration signatures, thereby enabling proactive maintenance. To classify various failure signatures, we have proposed a framework to interpret time-series and frequency-dependent data for determining failure types. This research exemplifies how merging data-driven methods with digital twin can improve the accuracy and reliability of condition monitoring. Additionally, we introduce a cloud-based architecture for the diagnosis of rotating machinery, utilizing Application Programming Interface (API) configurations, and develop a real-time dashboard for streaming and visualizing classified data, fostering immediate and informed decision-making.
{"title":"Advancing architectural frameworks for vibration signature classification in rotating machinery","authors":"Cole Yorston, Cheng Chen, Jaime Camelio","doi":"10.1177/09544054241260928","DOIUrl":"https://doi.org/10.1177/09544054241260928","url":null,"abstract":"Advancements in data-driven predictive maintenance have significantly improved digital twin applications for rotating machinery, offering robust solutions for smart manufacturing challenges. These improvements are crucial since equipment failures can cause extensive and costly disruptions to both maintenance schedules and operations. As precision and reliability are critical in production processes, undetected fluctuations in operating frequencies can swiftly escalate to complete part failure, leading to prolonged repairs and productivity loss. This study explores an integrated dataflow pipeline, specifically through Siemens’ MindSphere, to enable continuous predictive maintenance and enhance data acquisition and management. Particularly, conditions such as normal operation, mass balance, rotating imbalance, and mechanical looseness are classified using support vector machine (SVM), neural network (NN), and K-Nearest Neighbor (KNN) methods for the purpose of comparing results. Our results highlight the efficacy of ensemble techniques in collecting and diagnosing vibration signatures, thereby enabling proactive maintenance. To classify various failure signatures, we have proposed a framework to interpret time-series and frequency-dependent data for determining failure types. This research exemplifies how merging data-driven methods with digital twin can improve the accuracy and reliability of condition monitoring. Additionally, we introduce a cloud-based architecture for the diagnosis of rotating machinery, utilizing Application Programming Interface (API) configurations, and develop a real-time dashboard for streaming and visualizing classified data, fostering immediate and informed decision-making.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":1.9,"publicationDate":"2024-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141807938","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}
Pub Date : 2024-07-24DOI: 10.1177/09544054241245767
H. Xia, G. Zhao, Yang Zhang, Liang Li, Ning He, Hans Nørgaard Hansen
TiAl intermetallic alloy is a superior lightweight material with excellent performance, and its micro features or components have promising applications in manufacturing fields. In this work, an investigation of micro milling of microgroove arrays on TiAl alloy was studied. The effects of cutting parameters including the feed per tooth (fz) and depth of cut ( ap) on the milling force, surface morphology, surface roughness and burr size of the micro-slots were investigated. The wear types and mechanisms of the micro end mills were also studied. The results showed that the optimal cutting parameters were fz = 3.5 μm/z and ap = 4 μm, which provided the best surface roughness Sa of 152 nm, top-burr heights on up- and down-milling sides of 19 and 19.5 μm respectively. Using the optimized cutting parameters, microgrooves with a width of 500 μm, aspect ratio of 5 and array period of 10 were fabricated successfully. Surface topography, dimensional accuracy and perpendicularity of the microgroove arrays were characterized. Results demonstrated that an increase in the microgroove number, microgroove edge chipping as well as burrs of the entrance and exit increased gradually. The dimensional error between the obtained width and the designed width of the microgroove was less than 2%, and the slope of the sidewalls reached more than 89°. The wear mechanisms of the micro end mills were abrasive wear and adhesive wear, and wear types were coating delamination, cutting edge chipping, and tool nose breakage.
TiAl 金属间合金是一种性能优越的轻质材料，其微特征或组件在制造领域具有广阔的应用前景。在这项工作中，对 TiAl 合金微槽阵列的微铣削进行了研究。研究了切削参数（包括每齿进给量（fz）和切削深度（ap））对微槽的铣削力、表面形态、表面粗糙度和毛刺尺寸的影响。此外，还研究了微型立铣刀的磨损类型和机理。结果表明，最佳切削参数为 fz = 3.5 μm/z 和 ap = 4 μm，其最佳表面粗糙度 Sa 为 152 nm，上铣边和下铣边的毛刺高度分别为 19 μm 和 19.5 μm。利用优化的切削参数，成功制造出了宽度为 500 μm、纵横比为 5、阵列周期为 10 的微槽。对微槽阵列的表面形貌、尺寸精度和垂直度进行了表征。结果表明，随着微槽数量的增加，微槽边缘的崩裂以及入口和出口的毛刺逐渐增加。获得的微槽宽度与设计宽度之间的尺寸误差小于 2%，侧壁斜度大于 89°。微型立铣刀的磨损机理为磨料磨损和粘着磨损，磨损类型为涂层脱层、切削刃崩裂和刀头断裂。
{"title":"Research on production of microgroove arrays on TiAl intermetallic alloy by micro milling","authors":"H. Xia, G. Zhao, Yang Zhang, Liang Li, Ning He, Hans Nørgaard Hansen","doi":"10.1177/09544054241245767","DOIUrl":"https://doi.org/10.1177/09544054241245767","url":null,"abstract":"TiAl intermetallic alloy is a superior lightweight material with excellent performance, and its micro features or components have promising applications in manufacturing fields. In this work, an investigation of micro milling of microgroove arrays on TiAl alloy was studied. The effects of cutting parameters including the feed per tooth (fz) and depth of cut ( ap) on the milling force, surface morphology, surface roughness and burr size of the micro-slots were investigated. The wear types and mechanisms of the micro end mills were also studied. The results showed that the optimal cutting parameters were fz = 3.5 μm/z and ap = 4 μm, which provided the best surface roughness Sa of 152 nm, top-burr heights on up- and down-milling sides of 19 and 19.5 μm respectively. Using the optimized cutting parameters, microgrooves with a width of 500 μm, aspect ratio of 5 and array period of 10 were fabricated successfully. Surface topography, dimensional accuracy and perpendicularity of the microgroove arrays were characterized. Results demonstrated that an increase in the microgroove number, microgroove edge chipping as well as burrs of the entrance and exit increased gradually. The dimensional error between the obtained width and the designed width of the microgroove was less than 2%, and the slope of the sidewalls reached more than 89°. The wear mechanisms of the micro end mills were abrasive wear and adhesive wear, and wear types were coating delamination, cutting edge chipping, and tool nose breakage.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":1.9,"publicationDate":"2024-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141806742","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}
Pub Date : 2024-07-24DOI: 10.1177/09544054241260473
Yunliang Huo, Yunqing Zhou, Junbo Liu, Ming Zhang, Zhenlong Li
The adaptation of cutting tools is the key link in machining. Although a large amount of work has been done to achieve tool selection for a single feature, there is relatively little research on tool scheme adaptation for multi-feature parts. Considering the factors of matching, efficiency, cost, and environment, a comprehensive optimization method for a multi-feature part tool scheme is proposed in this work. First, the critical tool of a complex feature is defined, and a tool combination method with complex single features is proposed to generate an efficient tool strategy. Then, a tool scheme optimization model for multi-feature parts is constructed in which each machining feature is mapped to a game player in the model space, and the set of available tools is mapped to the player strategies. In addition, the classical evolutionary game algorithm is improved to adapt to the model, according to the difference in the features number and type of different parts. Finally, a square test piece is taken as a case to verify the proposed method. The result shows that the method presented in this work can efficiently obtain the customer-preferred tool scheme for the part.
{"title":"A comprehensive cutting tool adaptation method for multi-feature part based on evolutionary game algorithm","authors":"Yunliang Huo, Yunqing Zhou, Junbo Liu, Ming Zhang, Zhenlong Li","doi":"10.1177/09544054241260473","DOIUrl":"https://doi.org/10.1177/09544054241260473","url":null,"abstract":"The adaptation of cutting tools is the key link in machining. Although a large amount of work has been done to achieve tool selection for a single feature, there is relatively little research on tool scheme adaptation for multi-feature parts. Considering the factors of matching, efficiency, cost, and environment, a comprehensive optimization method for a multi-feature part tool scheme is proposed in this work. First, the critical tool of a complex feature is defined, and a tool combination method with complex single features is proposed to generate an efficient tool strategy. Then, a tool scheme optimization model for multi-feature parts is constructed in which each machining feature is mapped to a game player in the model space, and the set of available tools is mapped to the player strategies. In addition, the classical evolutionary game algorithm is improved to adapt to the model, according to the difference in the features number and type of different parts. Finally, a square test piece is taken as a case to verify the proposed method. The result shows that the method presented in this work can efficiently obtain the customer-preferred tool scheme for the part.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":1.9,"publicationDate":"2024-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141808272","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}
Pub Date : 2024-07-23DOI: 10.1177/09544054241260461
Dinesh Rajaram, E. Sooriyamoorthy, Amirthagadeswaran Koduvayur Sankaranarayanan
Casting is a process for the production of complex shapes. Defects are unavoidable in any casting process. An efficient method of eliminating such defects can improve the process capability of the casting system. Computer simulation can save time, resources, and money in foundry trials, but it necessitates more human effort in terms of preparing the inputs and appropriately interpreting the results. In this work, a new method for evaluating and optimizing gating system design utilizing a simulation tool is proposed. It is possible to automatically modify the gating design with the help of CAD and casting simulation software from a given initial design and boundary conditions, and to check whether the design is effective to eliminate defects. Further this takes less human effort, making it more useful for industrial applications. The suggested methodology is demonstrated by autonomously optimizing the gating system for two industrial components and validated by producing actual castings made in sand molds.
{"title":"Automated optimization of gating system through numerical simulation","authors":"Dinesh Rajaram, E. Sooriyamoorthy, Amirthagadeswaran Koduvayur Sankaranarayanan","doi":"10.1177/09544054241260461","DOIUrl":"https://doi.org/10.1177/09544054241260461","url":null,"abstract":"Casting is a process for the production of complex shapes. Defects are unavoidable in any casting process. An efficient method of eliminating such defects can improve the process capability of the casting system. Computer simulation can save time, resources, and money in foundry trials, but it necessitates more human effort in terms of preparing the inputs and appropriately interpreting the results. In this work, a new method for evaluating and optimizing gating system design utilizing a simulation tool is proposed. It is possible to automatically modify the gating design with the help of CAD and casting simulation software from a given initial design and boundary conditions, and to check whether the design is effective to eliminate defects. Further this takes less human effort, making it more useful for industrial applications. The suggested methodology is demonstrated by autonomously optimizing the gating system for two industrial components and validated by producing actual castings made in sand molds.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":1.9,"publicationDate":"2024-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141810873","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}
Pub Date : 2024-07-23DOI: 10.1177/09544054241261095
Xiaohong Lu, Ying Chen, Chen Cong, Kaidong Wang, Steven Y. Liang
The demands for aluminum alloy LF21 micro precision parts are increasing in the fields of aerospace, high-tech electronic products, and the other fields. Micro-milling is an effective technology for machining small LF21 precision parts. Cutting forces and temperature are crucial factors in micro-milling process, directly affect tool vibration, tool wear, and surface quality of the workpiece, and even result in large deformation of the tool and workpiece. Direct measurement of cutting forces during micro-milling requires high-precision and expensive instruments. Moreover, due to the small cutting area in micro-milling, it is challenging to achieve accurate measurements of cutting area temperature. Therefore, accurate prediction of cutting forces and temperature in micro-milling is urgent and challenging. Nowadays, there are few studies on prediction of cutting forces in micro-milling LF21. The study on prediction of temperature in micro-milling LF21 is still blank. To solve the above problems, this paper proposes a finite element method based on modeling for prediction of cutting forces and temperature in micro-milling LF21. ABAQUS software is adopted. First, the geometry models of the micro-milling tool and workpiece are established. Then, the assembly and mesh division of the established models are completed. Johnson-Cook constitutive model and Johnson-Cook damage criteria are used to describe the material constitutive relationship and chip separation criteria, respectively. The suitable tool-workpiece friction models are determined. Finally, the simulation of the micro-milling LF21 process is achieved. Experiments of micro-milling LF21 are conducted and the cutting forces are measured using the dynamometer. The validity of the built process simulation model and the correctness of the cutting force prediction results are verified by the comparison of experiment and simulation cutting forces. Then, the prediction of temperature is achieved based on the verified process simulation model of micro-milling LF21.
{"title":"Finite element method based modeling of cutting forces and cutting temperature in micro-milling LF21","authors":"Xiaohong Lu, Ying Chen, Chen Cong, Kaidong Wang, Steven Y. Liang","doi":"10.1177/09544054241261095","DOIUrl":"https://doi.org/10.1177/09544054241261095","url":null,"abstract":"The demands for aluminum alloy LF21 micro precision parts are increasing in the fields of aerospace, high-tech electronic products, and the other fields. Micro-milling is an effective technology for machining small LF21 precision parts. Cutting forces and temperature are crucial factors in micro-milling process, directly affect tool vibration, tool wear, and surface quality of the workpiece, and even result in large deformation of the tool and workpiece. Direct measurement of cutting forces during micro-milling requires high-precision and expensive instruments. Moreover, due to the small cutting area in micro-milling, it is challenging to achieve accurate measurements of cutting area temperature. Therefore, accurate prediction of cutting forces and temperature in micro-milling is urgent and challenging. Nowadays, there are few studies on prediction of cutting forces in micro-milling LF21. The study on prediction of temperature in micro-milling LF21 is still blank. To solve the above problems, this paper proposes a finite element method based on modeling for prediction of cutting forces and temperature in micro-milling LF21. ABAQUS software is adopted. First, the geometry models of the micro-milling tool and workpiece are established. Then, the assembly and mesh division of the established models are completed. Johnson-Cook constitutive model and Johnson-Cook damage criteria are used to describe the material constitutive relationship and chip separation criteria, respectively. The suitable tool-workpiece friction models are determined. Finally, the simulation of the micro-milling LF21 process is achieved. Experiments of micro-milling LF21 are conducted and the cutting forces are measured using the dynamometer. The validity of the built process simulation model and the correctness of the cutting force prediction results are verified by the comparison of experiment and simulation cutting forces. Then, the prediction of temperature is achieved based on the verified process simulation model of micro-milling LF21.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":1.9,"publicationDate":"2024-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141812877","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}
Pub Date : 2024-07-23DOI: 10.1177/09544054241255980
Rui Zhou, Junchi Jiang, Chunzhi Du, Shuaiyuan Lu
An Ant Lion Optimization algorithm based on elite Opposition-based learning and Cosine factors (OCALO) is proposed to address the problem of poor response and stability during heating process in high-speed 3D printing temperature system.The generation of the initial solution in OCALO algorithm is enhanced by the introduction of a new Tent-Logistic-Cotangent composite chaotic mapping, which guarantees the diversity of population. The PID parameters are optimized using the improved algorithm. Compared with two existing classical algorithms and three improved ALO algorithms, the proposed algorithm improves the convergence speed, global search ability and the ability to jump out of the local optimal solution. The outcomes of simulation and experimentation demonstrate that the algorithm improves the transient and steady-state performance of temperature control with better accuracy and robustness. It takes at least 123 s faster than other controllers to reach stability and is more than two times stronger than other PID controllers, making it better suited to high-speed 3D printing temperature systems.
{"title":"High-speed 3D printing temperature system with optimized PlD parameters based on improved ant lion optimization algorithm","authors":"Rui Zhou, Junchi Jiang, Chunzhi Du, Shuaiyuan Lu","doi":"10.1177/09544054241255980","DOIUrl":"https://doi.org/10.1177/09544054241255980","url":null,"abstract":"An Ant Lion Optimization algorithm based on elite Opposition-based learning and Cosine factors (OCALO) is proposed to address the problem of poor response and stability during heating process in high-speed 3D printing temperature system.The generation of the initial solution in OCALO algorithm is enhanced by the introduction of a new Tent-Logistic-Cotangent composite chaotic mapping, which guarantees the diversity of population. The PID parameters are optimized using the improved algorithm. Compared with two existing classical algorithms and three improved ALO algorithms, the proposed algorithm improves the convergence speed, global search ability and the ability to jump out of the local optimal solution. The outcomes of simulation and experimentation demonstrate that the algorithm improves the transient and steady-state performance of temperature control with better accuracy and robustness. It takes at least 123 s faster than other controllers to reach stability and is more than two times stronger than other PID controllers, making it better suited to high-speed 3D printing temperature systems.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":1.9,"publicationDate":"2024-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141812152","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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