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Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability最新文献

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Evaluation of Process Parameters Modifications on Directed Energy Deposition Manufactured Parts Obtained in a Hybrid Additive Manufacturing Machine 混合增材制造机中定向能沉积制件工艺参数修改的评价
Ana Beatriz B. Henriques, Paola L. de Aguiar, Raphael G. dos Santos, Joice Miagava
In order to combine advantages of both additive and subtractive manufacturing, hybrid machine tools have been developed. In the hybrid process, directed energy deposition (DED) is the most used additive manufacturing technology due to its adaptability to CNC milling centers. However, in order to assure the integrity of a printed part, several process parameters must be set appropriately. Not only there are several parameters, but also some of these parameters influence different variables — e.g.: scan speed influences both the energy input per unit area and the powder volume that is deposited. In addition, another fact that complicates the achievement of a good quality in a workpiece is that some relevant parameters for additive manufacturing cannot be controlled due to CNC milling center constraints (e.g.: atmosphere). In this work, laser power (280 to 340 W) and scan speed (5 to 7 mm/s) were systematically varied to print 316L test samples with the aim of building a quality matrix. In the future, this matrix will be used to create strategies to optimize the quality of printed parts. Optical stereoscopy shows that the higher the laser power, the higher the sample, indicating that more powder is melted and deposited with an increasing laser power. By fixing the laser power and increasing the scan speed, printed samples were lower, indicating that less powder was deposited. Other parameters were preliminarily tested — e.g.: sample size and shield gas flow. Decreasing the sample size from 9 to 6 mm was sufficient to double the sample height, showing that the heat transfer rate was dramatically changed. Findings of this study shows that all process parameters act together and are determining factors for a good quality printed part. Moreover, it was noted that sample integrity is very sensitive to minimal changes in some process parameters.
为了结合增材制造和减材制造的优点,混合动力机床得到了发展。在混合工艺中,定向能沉积(DED)由于其对CNC铣削中心的适应性而成为应用最多的增材制造技术。然而,为了保证打印件的完整性,必须适当设置几个工艺参数。不仅有几个参数,而且其中一些参数影响不同的变量-例如:扫描速度影响每单位面积的能量输入和沉积的粉末体积。此外,另一个使工件获得良好质量变得复杂的事实是,由于CNC铣削中心的限制(例如:气氛),增材制造的一些相关参数无法控制。在这项工作中,系统地改变激光功率(280至340 W)和扫描速度(5至7 mm/s)来打印316L测试样品,目的是建立一个质量矩阵。在未来,该矩阵将用于创建策略,以优化打印部件的质量。光学立体观察表明,激光功率越高,样品质量越高,表明随着激光功率的增加,更多的粉末被熔化和沉积。通过固定激光功率和提高扫描速度,打印的样品更低,表明沉积的粉末更少。其他参数也进行了初步测试,例如:样品尺寸和保护气体流量。将样品尺寸从9 mm减小到6 mm足以使样品高度增加一倍,表明传热速率发生了显著变化。研究结果表明,所有工艺参数共同作用,是决定高质量打印件的因素。此外,还注意到样品的完整性对某些工艺参数的微小变化非常敏感。
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引用次数: 0
Assessing the Impacts of Real-Time Price Prediction Quality on Demand Response Management for Sustainable Smart Manufacturing 评估实时价格预测质量对可持续智能制造需求响应管理的影响
Lingxiang Yun, Lin Li
The emerging smart manufacturing technologies pave the way for flexible and autonomous monitoring and control of complex manufacturing systems, which facilitate the implementation of real-time price (RTP) based demand response management towards sustainability. The demand response management requires scheduling of smart manufacturing systems in advance, and thus the quality of RTP predictions directly impacts the performance of demand response. Although several prediction evaluation metrics are currently available, they are designed to show the similarities between prediction and actual RTP, which are not necessarily related to demand response performance. Therefore, in this study, the daily energy cost reductions obtained by solving a demand response management problem are adopted as an indicator of demand response performance. Six commonly used evaluation metrics are examined, and their correlations with energy cost reductions are investigated. In addition, a new metric called k-peak distance considering the characteristics of the demand response problem is proposed and compared with the other six metrics. The case studies show that the proposed metric has two to four times higher correlation with energy cost reductions and only about half of the standard error compared to other metrics. The results indicate that the proposed metric can better represent the prediction quality in the demand response problem.
新兴的智能制造技术为复杂制造系统的灵活和自主监测和控制铺平了道路,这有助于实现基于实时价格(RTP)的需求响应管理,以实现可持续性。需求响应管理需要对智能制造系统进行提前调度,因此RTP预测的质量直接影响到需求响应的性能。尽管目前有几个预测评估度量是可用的,但它们的设计目的是显示预测和实际RTP之间的相似性,而这并不一定与需求响应性能相关。因此,在本研究中,通过解决需求响应管理问题而获得的每日能源成本降低作为需求响应绩效的指标。研究了六种常用的评估指标,并研究了它们与能源成本降低的相关性。此外,考虑到需求响应问题的特点,提出了一个新的度量,称为k峰距离,并与其他六个度量进行了比较。案例研究表明,与其他指标相比,拟议指标与能源成本降低的相关性高2到4倍,标准误差仅为标准误差的一半左右。结果表明,该度量能较好地反映需求响应问题的预测质量。
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引用次数: 0
Selective Laser Melting and Mechanical Properties of Oxide Dispersion Strengthened Haynes 214 Alloy 氧化物弥散强化Haynes 214合金的选择性激光熔化及力学性能
B. Poudel, H. Nguyen, Aaron O'Neil, Mohsan Uddin Ahmad, Z. Qu, P. Kwon, Haseung Chung
Haynes 214, a nickel-based superalloy, and its oxide dispersion-strengthened (ODS) versions (addition of 0.3, and 1.5 wt. % yttria (Y2O3)) have been successfully fabricated using selective laser melting (SLM). For each feedstock formulation, optimal processing conditions were identified and high temperature tensile testing coupons were produced. Feedstock preparation and laser scanning strategy have been proven to be critical in the dispersion of nanoparticles in the metal matrix, as well as preventing the formation of extensive crack networks. The impact of Y2O3 addition on the high-temperature tensile properties of Haynes 214 was evaluated and discussed.
Haynes 214是一种镍基高温合金,其氧化物弥散强化(ODS)版本(添加0.3和1.5 wt. %的钇(Y2O3))已成功地用选择性激光熔化(SLM)制备。针对每种原料配方,确定了最佳工艺条件,并制作了高温拉伸试验片。原料制备和激光扫描策略已被证明是纳米颗粒在金属基体中的分散以及防止广泛裂纹网络形成的关键。评价并讨论了添加Y2O3对Haynes 214高温拉伸性能的影响。
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引用次数: 2
Anomaly Scoring Model for Diagnosis on Machine Condition and Health Management 机器状态诊断与健康管理的异常评分模型
B. Joung, Zhongtian Li, J. Sutherland
The reliability of manufacturing equipment is critical for ensuring the productivity and energy efficiency of a manufacturing facility. An unexpected machine breakdown may lead to unexpected downtime, disruption of manufacturing schedule, lower production efficiency, higher operation and maintenance cost. The recent development in machine learning and artificial intelligence enables data-driven Predictive Maintenance (PdM) by means of perceiving the dynamics of manufacturing systems and abstracting them into learnable features to provide a better interpretation of machine failures or unplanned downtimes. PdM, often translated to Prognostics and Health Management (PHM), aims to continue the optimal/normal operation of manufacturing systems. Often, vibration is used as a proxy of an early indicator of impending failure. In this study, tri-axial acceleration data collected from the two different machines are utilized. PdM-based strategies for machine condition monitoring and smart scheduling of equipment maintenance using an anomaly scoring model are discussed for two critical elements in a manufacturing system: 1) Chiller 2) Compressor. An anomaly scoring model is developed to extract meaningful information from the vibration data.
制造设备的可靠性对于确保生产设施的生产力和能源效率至关重要。意外的机器故障可能会导致意外停机,扰乱生产计划,降低生产效率,增加运行和维护成本。机器学习和人工智能的最新发展通过感知制造系统的动态并将其抽象为可学习的特征来实现数据驱动的预测性维护(PdM),从而更好地解释机器故障或意外停机。PdM通常被翻译为预测和健康管理(PHM),旨在使制造系统保持最佳/正常运行。通常,振动被用作即将发生故障的早期指示的代理。在本研究中,使用了从两台不同的机器收集的三轴加速度数据。针对制造系统中的两个关键部件:1)冷水机组2)压缩机,讨论了基于pdm的机器状态监测策略和基于异常评分模型的设备维护智能调度。为了从振动数据中提取有意义的信息,建立了异常评分模型。
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引用次数: 0
Joining of Metal-Thermoplastic-Tube-Joints by Hydraulic Expansion 金属-热塑性管-接头的水力膨胀连接
F. Weber, Peter Lehmenkühler, M. Hahn, A. Tekkaya
To encounter current issues regarding climate change, the hybridization of structures with lighter, often dissimilar, materials is an essential cornerstone of lightweight design. The different mechanical behavior of these materials results in challenges in terms of joining. This paper utilizes the joining process by hydraulic expansion to manufacture tube-to-tube joints of aluminum alloy AA6060 T66 and thermoplastic polycarbonate (Lexan) at room temperature. In contrast to metals, elastic and plastic strains coexist in thermoplastics from the beginning of deformation. Based on the theory of linear elasticity, an equation was derived to calculate the fluid pressure that expands the polycarbonate up to a strain value where plastic strains start to increase significantly in comparison to elastic strains. Tensile tests of the joined tubes revealed that the transferable tensile load increased approximately exponentially with increasing plastic deformation of the polycarbonate. With ongoing plastic deformation, micro-cracks appeared and merged within the thermoplastic. The appearance of these so-called crazes had no negative influence on the transferable load within the range of applied fluid pressure.
为了应对当前有关气候变化的问题,结构与更轻、通常不同的材料的杂交是轻量化设计的重要基石。这些材料的不同力学性能导致了连接方面的挑战。本文采用液压膨胀连接工艺,在室温下制造了铝合金AA6060 T66与热塑性聚碳酸酯(Lexan)的管对管连接。与金属相反,热塑性塑料从变形开始就存在弹性和塑性应变。基于线弹性理论,推导出了使聚碳酸酯膨胀至某一应变值的流体压力方程,此时塑性应变开始比弹性应变显著增加。连接管的拉伸试验表明,随着聚碳酸酯塑性变形的增加,可转移拉伸载荷近似呈指数增长。随着塑性变形的不断进行,热塑性材料内部出现微裂纹并融合。这些所谓的裂纹的出现对施加流体压力范围内的可转移载荷没有负面影响。
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引用次数: 0
Decision Support for Locating Manufacturing Plants in Emerging Economies Using a Reliability Approach 基于可靠性方法的新兴经济体制造业选址决策支持
M. Gadalla, Ahmed E. Azab
In today’s distributed manufacturing reality, investors worldwide are faced with the dilemma of deciding on the optimal geographic spot for their manufacturing plants. On the one hand, emerging economies could be appealing because of their cheap labor as well as possibly their lack of or reduced regulations, litigation, and paperwork in some cases. On the other hand, these very same emerging economies can be quite risky because of the lack of stability of their political systems and hence, the associated economic volatility. Such economies can collapse in a relatively short period of time due to factors such as political instability, corruption, lack of democracy and the rule of law, social and racial injustices, and religious extremism, to name a few. In this paper, we propose a modeling approach where an economy is represented as an engineering system, the lifespan of which is subject to potential conditions, events, and failure modes. Such conditions and factors in the face of these fragile economies are modeled as pushers and deflators contributing to their instability. Hence, all laws of Reliability Engineering can be used to decide on the probability of success of such a system and its lifetime in the face of all uncertainty and given risks in today’s global climate. It is imperative that the health of the economic climate is a critical element solving the facility location and allocation problem; this entails deciding on large manufacturing investments in the form of new manufacturing plants being constructed and the accompanied supply chains. Enablers to allow for packageable manufacturing systems easier to relocate in the wake of this uncertain economic turmoil are also discussed. System Dynamics will be used as future work to account for the forces (deflators and pushers) when quantifying the proposed metrics. AI and Data Analytics techniques are also recommended to quantify the reliability parameters.
在当今的分布式制造现实中,世界各地的投资者都面临着为其制造工厂选择最佳地理位置的困境。一方面,新兴经济体可能具有吸引力,因为它们的廉价劳动力,以及在某些情况下可能缺乏或减少监管、诉讼和文书工作。另一方面,同样是这些新兴经济体,由于其政治体系缺乏稳定性,因此也会出现相关的经济波动,因此风险可能相当大。由于政治不稳定、腐败、缺乏民主和法治、社会和种族不公正以及宗教极端主义等因素,这些经济体可能在相对较短的时间内崩溃。在本文中,我们提出了一种建模方法,其中将经济表示为工程系统,其寿命受潜在条件、事件和失效模式的影响。这些脆弱经济体面临的条件和因素被建模为造成其不稳定的推动者和平减者。因此,在当今的全球气候下,可靠性工程的所有定律都可以用来决定这样一个系统的成功概率和它的生命周期,面对所有的不确定性和给定的风险。经济环境的健康是解决设施选址和配置问题的关键因素;这需要决定大型制造业投资的形式,包括正在建设的新制造工厂和伴随的供应链。在这种不确定的经济动荡之后,还讨论了允许可封装制造系统更容易搬迁的推动因素。系统动力学将作为未来的工作,在量化所提议的指标时,解释力(平减和推动)。人工智能和数据分析技术也被推荐用于量化可靠性参数。
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引用次数: 0
Thin-Film Nitrate Sensor Performance Prediction Based on Image Analysis and Credibility Data to Enable a Certify As Built Framework 基于图像分析和可信度数据的薄膜硝酸盐传感器性能预测,以实现认证框架
Xihui Wang, Ajanta Saha, Ye Mi, A. Shakouri, Muhammad Ashraful Alam, G. Chiu, J. Allebach
In the modern industrial setting, there is an increasing demand for all types of sensors. The demand for both the quantity and quality of sensors is increasing annually. Our research focuses on thin-film nitrate sensors in particular, and it seeks to provide a robust method to monitor the quality of the sensors while reducing the cost of production. We are researching an image-based machine learning method to allow for real-time quality assessment of every sensor in the manufacturing pipeline. It opens up the possibility of real-time production parameter adjustments to enhance sensor performance. This technology has the potential to significantly reduce the cost of quality control and improve sensor quality at the same time. Previous research has proven that the texture of the topical layer (ion-selective membrane (ISM) layer) of the sensor directly correlates with the performance of the sensor. Our method seeks to use the correlation so established to train a learning-based system to predict the performance of any given sensor from a still photo of the sensor active region, i.e. the ISM. This will allow for the real-time assessment of every sensor instead of sample testing. Random sample testing is both costly in time and labor, and therefore, it does not account for all of the individual sensors. Sensor measurement is a crucial portion of the data collection process. To measure the performance of the sensors, the sensors are taken to a specialized lab to be measured for performance. During the measurement process, noise and error are unavoidable; therefore, we generated credibility data based on the performance data to show the reliability of each sensor performance signal at each sample time. In this paper, we propose a machine learning based method to predict sensor performance using image features extracted from the non-contact sensor images guided by the credibility data. This will eliminate the need to test every sensor as it is manufactured, which is not practical in a high-speed roll-to-roll setting, thus truely enabling a certify as built framework.
在现代工业环境中,对各种类型的传感器的需求不断增加。对传感器数量和质量的需求每年都在增加。我们的研究重点是薄膜硝酸盐传感器,并寻求提供一种可靠的方法来监测传感器的质量,同时降低生产成本。我们正在研究一种基于图像的机器学习方法,以便对制造管道中的每个传感器进行实时质量评估。它开辟了实时生产参数调整的可能性,以提高传感器的性能。该技术有可能显著降低质量控制成本,同时提高传感器质量。以往的研究已经证明,传感器局部层(离子选择膜(ISM)层)的质地直接关系到传感器的性能。我们的方法试图使用这样建立的相关性来训练一个基于学习的系统,以从传感器有源区域(即ISM)的静态照片中预测任何给定传感器的性能。这将允许实时评估每个传感器,而不是样品测试。随机抽样测试在时间和人力上都很昂贵,因此,它不能解释所有的单个传感器。传感器测量是数据采集过程中至关重要的一部分。为了测量传感器的性能,传感器被带到专门的实验室进行性能测量。在测量过程中,噪声和误差是不可避免的;因此,我们根据性能数据生成可信度数据,以显示每个传感器在每个采样时间的性能信号的可靠性。在本文中,我们提出了一种基于机器学习的方法,利用从非接触式传感器图像中提取的图像特征,在可信度数据的指导下预测传感器的性能。这将消除在制造过程中对每个传感器进行测试的需要,这在高速滚对滚设置中是不切实际的,从而真正实现了构建框架的认证。
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引用次数: 0
Thermal Analyses of Electrically Assisted Forming 电辅助成形的热分析
T. Grimm, L. Mears
Electrically assisted manufacturing (EAM) is defined as the direct application of electricity to a workpiece in situ with a manufacturing process. This is commonly used in forming to reduce the flow stress and increase the ductility of metals. Under certain conditions, there seem to be effects of the electricity that occur in addition to the inherent resistive heating in metals. This electroplastic effect is often deduced by estimating temperatures through analytical or numerical simulations and comparing this to the temperatures required to effect thermal stress reductions observed in experimental tests. For tests which utilized pulsed or AC currents, an RMS current value may be used to simplify simulations since current transience can be averaged to a constant representative value. However, there is often no justification of this assumption and it is possible that assumption could lead to erroneous results. Various assumptions applied to EAM research are explicitly explored herein to determine their validity in thermal estimations. It was concluded that AC, square wave, and sawtooth currents at frequencies greater than 1 Hz, or pulses from power supplies with significant ripple, can be approximated with a DC current of similar RMS value to obtain similar thermal estimations. Simulation geometries should incorporate as much of the experimental setup as possible. An example from literature was used to test several other assumptions as well, including the use of analytical simulations, rather than numerical.
电辅助制造(EAM)被定义为在制造过程中直接将电应用于工件。这通常用于成形,以减少流动应力和增加金属的延展性。在某些条件下,除了金属固有的电阻加热外,似乎还会产生电的影响。这种电塑性效应通常是通过分析或数值模拟来估计温度,并将其与实验测试中观察到的影响热应力降低所需的温度进行比较来推断的。对于使用脉冲或交流电流的测试,可以使用均方根电流值来简化模拟,因为电流瞬态可以平均为一个恒定的代表性值。然而,这种假设往往没有理由,而且这种假设有可能导致错误的结果。本文明确探讨了应用于EAM研究的各种假设,以确定它们在热估算中的有效性。结论是,频率大于1hz的交流、方波和锯齿电流,或来自具有显著纹波的电源的脉冲,可以用RMS值相似的直流电流进行近似,从而获得相似的热估计。模拟几何图形应尽可能多地包含实验设置。文献中的一个例子也被用来检验其他几个假设,包括使用分析模拟,而不是数值模拟。
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引用次数: 1
Collaborative Filtering Recommendation Based Trust Evaluation Method for Cloud Manufacturing Service 基于协同过滤推荐的云制造服务信任评估方法
Jiang-Xiao Pei, Wang Mingxing, Liao Xiaobin, Yin Chao
In the cloud manufacturing (CMfg) model, users can get various high-quality, efficient manufacturing services (MSs) on-demand through the connection between the Internet of things and cloud platforms. While the problem of the reliable identification of MSs is one of the keys to the efficient operation of the cloud platform and the popularization and application of CMfg. To address this problem, a trust evaluation index system and a credible evaluation model considered the similarity and recommendation reliability between users’ behaviors are proposed in this paper. Based on the analysis of the factors that affect the credibility of MSs in the cloud environment, the analytic hierarchy process (AHP) is introduced to calculate the weight of each trusted evaluation index. In addition, a trusted estimation method based on collaborative filtering recommendation algorithm (CFRA) is proposed to solve the model and judge whether the MSs are trusted to the target user according to the obtained predictive valuation value. Finally, compared with PSO and GA, an example is employed to demonstrate the validity and effectiveness of the model and method, which can find a trusted MS for users and greatly save retrieval time.
在云制造(CMfg)模式中,用户可以通过物联网与云平台的连接,按需获得各种优质、高效的制造服务。而MSs的可靠识别问题是云平台高效运行和CMfg推广应用的关键之一。针对这一问题,本文提出了考虑用户行为之间相似度和推荐可靠性的信任评价指标体系和可信度评价模型。在分析影响云环境下MSs可信度因素的基础上,引入层次分析法(AHP)计算各可信评价指标的权重。此外,提出了一种基于协同过滤推荐算法(CFRA)的可信估计方法,对模型进行求解,并根据得到的预测评价值判断是否信任目标用户。最后,通过与粒子群算法和遗传算法的比较,验证了该模型和方法的有效性,为用户找到了一个可信的MS,大大节省了检索时间。
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引用次数: 0
Roll to Roll Manufacturing and In-Line Imaging and Characterization of Functional Films 卷对卷制造和功能薄膜的在线成像和表征
N. Glassmaker, Ye Mi, M. Cakmak, A. Shakouri
Roll-to-roll manufacturing is a promising platform to produce low cost, high quality electrical components and sensors for Internet of Things (IoT) applications. Within the roll-to-roll laboratories at Purdue University, a range of processes and machines have been developed to: 1) print patterns of conductive and sensing materials for use in electronic sensors, 2) cast films precisely with integrated functional materials, and 3) monitor quality of the printing and casting processes in-line in real time. A major development is the custom-designed and built Maxwell coating machine, which has enabled substantial quality improvements in slot-die coatings, as demonstrated by precise in-line thickness monitoring and imaging. As an illustrative example, we will show how we converted a design for a printed ion-selective electrode from a batch process to a roll-to-roll process. In-line process monitoring of coating thickness allowed us to identify high variability in the coating thickness due to an interaction between underlying printed electrodes and the drying process. By modifying the drying process, we demonstrated a substantial improvement as evidenced by the same in-line measurement technique. The overall process integrates several existing machines and processes in a novel way to create functional parts continuously, with data on individual parts gathered in real time.
卷对卷制造是一个很有前途的平台,可以为物联网(IoT)应用生产低成本、高质量的电子元件和传感器。在普渡大学的卷对卷实验室里,一系列的工艺和机器已经被开发出来:1)打印用于电子传感器的导电和传感材料的图案,2)用集成的功能材料精确地铸造薄膜,3)实时在线监控印刷和铸造过程的质量。一个主要的发展是定制设计和制造的Maxwell涂层机,它使槽模涂层的质量得到了实质性的提高,正如精确的在线厚度监测和成像所证明的那样。作为一个说明性的例子,我们将展示我们如何将印刷离子选择电极的设计从批处理转换为卷对卷处理。涂层厚度的在线过程监测使我们能够识别由于底层印刷电极和干燥过程之间的相互作用而导致的涂层厚度的高度可变性。通过修改干燥过程,我们展示了一个实质性的改进,证明了同样的在线测量技术。整个过程以一种新颖的方式集成了几个现有的机器和过程,以连续地创建功能部件,实时收集单个部件的数据。
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引用次数: 1
期刊
Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability
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