Manufacturing Letters最新文献_第10页

Batch-sizing and machinability data systems for milling operations: An optimal sustainable cost of quality approach 铣削操作的批量大小和可加工性数据系统：最佳可持续质量成本法

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.006

Abdulnasser El-Gaddar , Ahmed Azab , Mohammed Fazle Baki

Nowadays, manufacturers make every effort to achieve a higher quality of their products at an attractive cost. With all the introduced legislation and incentives in the developed world to address global warming, machining shops in the West also strive to cut greenhouse emissions. This article offers an optimal approach to the micro Computer-Aided Process Planning (CAPP) problem to optimize the internal quality cost and buffering effect while keeping the environmental impact low. To optimize the machining parameters, the mathematical model is developed for different milling operations, face, side, and peripheral. cutting speed, feed rate, axial depth of cut, radial depth of cut, nose radius, and batch sizing while maximizing profit and meeting customer demand. A Mixed-Integer Nonlinear Programming (MINLP) model is formulated and solved using Classical Constrained Nonlinear Optimization (CCNO) and Genetic Algorithms (GAs). Surface roughness, used as a metric to evaluate the desired quality level of a finished machined part type, is modeled as a Gaussian random variable to model the surface roughness of the machined part utilizing a cumulative normal distribution. The ratio of rework and scrap is calculated in terms of the surface roughness of the machined part shifting away from the target and exceeding upper and lower specification limits. The internal failure cost model, addressing both scrap and rework, is developed based on Taguchi’s quadratic loss function. CCNO is employed to validate the results obtained by GAs, relaxing the lot-sizing integrality constraint and, thus, the convexity of the produced relaxed model. An iterative method employing a developed multi-regression model is used to solve for the expended power consumption (an inherent highly nonlinear environmental criterion of the developed model) within both GAs and CCNO. This study reveals that the machining parameters substantially impact the cost components of the objective function as well as the scrap and rework quantities. A stringent quality cost target can force the model to optimize the feed rate and nose radius to minimize the internal failure quality cost while improving the environmental impact, including direct and indirect power consumption and CO₂ emissions considerations.

如今，制造商们都在竭尽全力以具有吸引力的成本实现更高的产品质量。发达国家为应对全球变暖出台了各种立法和激励措施，西方国家的机械加工车间也在努力减少温室气体排放。本文为微型计算机辅助工艺规划（CAPP）问题提供了一种优化方法，以优化内部质量成本和缓冲效果，同时保持较低的环境影响。为了优化加工参数，本文针对不同的铣削操作、面铣削、侧铣削和周边铣削，以及切削速度、进给量、轴向切削深度、径向切削深度、刀头半径和批量大小，建立了数学模型，同时实现利润最大化并满足客户需求。利用经典约束非线性优化（CCNO）和遗传算法（GAs）建立并解决了一个混合整数非线性编程（MINLP）模型。表面粗糙度是用来评估加工零件类型的理想质量水平的指标，该模型是一个高斯随机变量，利用累积正态分布对加工零件的表面粗糙度进行建模。返工率和废品率是根据加工零件表面粗糙度偏离目标和超出规格上下限的情况计算得出的。针对废品和返工的内部故障成本模型是基于田口二次损失函数开发的。采用 CCNO 验证遗传算法获得的结果，放宽了批量大小积分约束，从而放宽了生成的放宽模型的凸性。在 GA 和 CCNO 中都采用了一种迭代方法，利用开发的多元回归模型来求解消耗的功率消耗（开发的模型固有的高度非线性环境准则）。这项研究表明，加工参数对目标函数的成本部分以及废品和返工数量有重大影响。严格的质量成本目标可迫使模型优化进给速度和鼻端半径，以最大限度地降低内部故障质量成本，同时改善对环境的影响，包括直接和间接的电力消耗和二氧化碳排放。

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引用次数: 0

A Welcome from the Editor-in-Chief 主编致欢迎辞

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.004

Laine Mears (Editor in Chief, SME Manufacturing Letters)

引用次数: 0

Jerk limited continuous tool path generation for flexible systems in non-cartesian coordinate systems 在非笛卡尔坐标系中为柔性系统生成限位连续刀具路径

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.047

Mehrdad Sadeghieh , Sayyed Mohammadreza Mofidi , Ali Hosseini , Behnam Moetakef-Imani

Inspired by computer numerical control (CNC) technology and drastic changes in the world of electronics and microcontrollers, the idea of using non-cartesian coordinate system for CNC machines became a topic of interest. Non-cartesian coordinate systems provide freedom of movement in systems with large working spaces where high dimensional accuracy is not a prime concern. Applications of such systems can be found in murals, where a painting is applied to a large wall of any arbitrary build material. In the present paper, a new design was introduced to automate the process of drawing murals on large surfaces. The proposed mechanism utilized chain and sprocket to overcome the size limitations of traditionally available x-y tables. In addition to that, the developed mechanism does not utilize the common robust structures used in the conventional CNC systems and the tool motion is created using flexible arms that are not heavily constrained. The effect of systems unwanted vibration has been eliminated using continuous trajectory and kinematic profiles. Parametric curve interpolation algorithms for trajectory planning were implemented to increase the flexibility of drawing complex curves. Parametric curves such as B-spline and non-uniform rational B-spline (NURBS) were employed to generate a jerk limited trajectory for motion control and extraction of kinematic profiles. Such trajectory constrains the jerk of the system and guarantees a smooth motion free of feed-rate fluctuations. Compared to other methods available for extracting the kinematic profiles, jerk limited method decreases the travel time and trajectory error. Ultimately, motion commands were produced by using kinematic profiles and the second order Taylor interpolator. STM32746ZG card was used as the main processor and two stepper motors controlled by a Bit Pattern interpolation algorithm were utilized to drive the proposed mechanism. The input pulses of stepper motors were stored as binary bits and transmitted to drivers in real-time. The feedback was also evaluated by two rotary encoders, placed at the end of the motors’ shafts. Encoder data were acquired and transmitted using a TCP/IP protocol to guarantee zero data loss during the transmission.

受计算机数控（CNC）技术以及电子和微控制器领域急剧变化的启发，在数控机床上使用非笛卡尔坐标系的想法成为人们感兴趣的话题。非笛卡尔坐标系为具有较大工作空间的系统提供了运动自由度，在这种情况下，高尺寸精度并不是首要考虑因素。此类系统的应用可以在壁画中找到，即在任意材料的大墙上绘制一幅画。本文介绍了一种新的设计，用于在大型表面上自动绘制壁画。所提出的机构利用链条和链轮来克服传统 X-Y 工作台的尺寸限制。此外，所开发的机构没有使用传统数控系统中常见的坚固结构，而是使用没有严重约束的柔性臂来实现工具运动。利用连续轨迹和运动曲线消除了系统不必要的振动影响。为提高绘制复杂曲线的灵活性，采用了用于轨迹规划的参数曲线插值算法。采用 B-样条曲线和非均匀有理 B-样条曲线（NURBS）等参数曲线来生成用于运动控制和运动曲线提取的运动受限轨迹。这种轨迹限制了系统的颠簸，并保证了平稳的运动，不受进给率波动的影响。与其他提取运动学轮廓的方法相比，限制运动的方法减少了移动时间和轨迹误差。最终，通过使用运动曲线和二阶泰勒插值器生成了运动指令。STM32746ZG 卡被用作主处理器，两个由比特模式插值算法控制的步进电机被用来驱动拟议的机构。步进电机的输入脉冲被存储为二进制位，并实时传输给驱动器。此外，还通过安装在电机轴端部的两个旋转编码器对反馈进行评估。编码器数据通过 TCP/IP 协议获取和传输，以保证在传输过程中不会丢失数据。

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引用次数: 0

Exploring the potential of coal derived graphite as next generation lubricant additive for multifunctional applications 探索煤衍生石墨作为下一代多功能润滑油添加剂的潜力

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.035

K. Uday Venkat Kiran , Alexandar Azenkeng , Sougata Roy

In the present study, the friction and wear characteristics of steel/steel contact under reciprocating sliding conditions were investigated using composite mixtures made from Polyalphaolefin 4 (PAO4) as base oil lubricant and North Dakota lignite-derived graphite (LG) as high-value carbon additive. The results show that addition of 1 wt% LG to PAO4 led to a reduction in the friction coefficient and wear volume by ∼15 % and ∼13 %, respectively. In addition, the oxidation induction time (OIT) at 160 °C was increased by ∼29 %, which further indicates good stability of the formulated composite lubricant against oxidative degradation. The primary wear mechanism on AISI 52100 steel flat and counter-body was found to be abrasive wear under high-contact stress reciprocating sliding conditions, where tribo-oxide films of 100–200 nm were observed on the wear tracks of 52100 steel surfaces using focused ion beam scanning transmission electron microscopy (FIB-STEM). Furthermore, cross-sectional analysis of the wear track of AISI 52100 steel revealed that 1 wt% of LG additive reduced the thickness of the sub-surface deformation zone by 44 %, which indicates higher load-bearing capacity and improved wear resistance.

本研究使用聚α烯烃 4（PAO4）作为基础油润滑剂和北达科他州褐煤衍生石墨（LG）作为高价值碳添加剂制成的复合混合物，研究了往复滑动条件下钢/钢接触的摩擦和磨损特性。结果表明，在 PAO4 中添加 1 wt% 的 LG 可使摩擦系数和磨损量分别降低 ∼ 15 % 和 ∼ 13 %。此外，160 °C 下的氧化诱导时间（OIT）增加了 ∼ 29 %，这进一步表明所配制的复合润滑剂具有良好的抗氧化降解稳定性。利用聚焦离子束扫描透射电子显微镜（FIB-STEM）在 52100 钢表面的磨损轨迹上观察到 100-200 nm 的三氧化物薄膜，发现 AISI 52100 钢平面和反面体的主要磨损机制是高接触应力往复滑动条件下的磨料磨损。此外，对 AISI 52100 钢磨损轨迹的横截面分析表明，1 wt% 的 LG 添加剂可将表面下变形区的厚度减少 44%，这表明该添加剂具有更高的承载能力和耐磨性。

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引用次数: 0

Use of magnetic fields to impact glass-transition and crystallization during manufacturing of ZBLAN optical fibers 利用磁场影响 ZBLAN 光纤制造过程中的玻璃转变和结晶过程

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.053

Yashdeep, Sathyan Subbiah

ZBLAN (ZrF₄-BaF₂-LaF₃-AlF₃-NaF) is the most stable glass among the Heavy Metal Fluoride (HMF) family and has a wide range of applications in medical industry, telecommunication, IR transmission, among others. But, due to crystal formation while manufacturing of ZBLAN fiber its theoretical minimum loss has not been achieved yet. Some techniques such as high cooling rate and microgravity conditions have been utilized to reduce the crystal formation but are challenging to implement during manufacturing of these fibers. Alternatively, magnetic field (MF), also a body force like gravity, is expected to influence the crystal formation mechanism and glass kinetics. In this work, ZBLAN glass is processed under magnetic fields of various intensities while simulating fiber drawing manufacturing process conditions. Then, the processed ZBLAN is analyzed using Differential Scanning Calorimetry (DSC) at varying scanning rates. Various glass kinetics parameters such as activation energy, fragility, and preferred crystallization mechanism in terms of Avrami parameter (n) have been analyzed. The glass transition temperature (T_g) increases for a given sample as scanning rate (β) increases. Samples processed under varying magnetic fields, at the same scanning rate, displayed higher glass transition temperatures. Also, when the magnetic field increases, the activation energy required for glass transition decreases, and the fragility index (m) decreases. There is also a preference for surface crystallization over volume crystallization. These results encourage application of magnetic fields for reducing crystal formation while processing ZBLAN glass.

ZBLAN（ZrF4-BaF2-LaF3-AlF3-NaF）是重金属氟化物（HMF）家族中最稳定的玻璃，在医疗行业、电信、红外传输等领域有着广泛的应用。但是，由于在制造 ZBLAN 光纤时晶体的形成，其理论上的最小损耗尚未达到。一些技术，如高冷却率和微重力条件，已被用来减少晶体的形成，但在这些光纤的制造过程中实施具有挑战性。另外，磁场（MF）与重力一样也是一种体力，预计也会影响晶体形成机制和玻璃动力学。在这项工作中，ZBLAN 玻璃是在不同强度的磁场下进行加工的，同时模拟了纤维拉伸制造工艺条件。然后，使用差示扫描量热法（DSC）以不同的扫描速率对加工后的 ZBLAN 进行分析。分析了各种玻璃动力学参数，如活化能、脆性和以阿夫拉米参数（n）表示的优先结晶机制。给定样品的玻璃化转变温度（Tg）随着扫描速率（β）的增加而升高。在相同扫描速率下，在不同磁场中处理的样品显示出更高的玻璃化转变温度。此外，当磁场增加时，玻璃转化所需的活化能降低，脆性指数 (m) 也随之降低。此外，表面结晶比体积结晶更有优势。这些结果鼓励在加工 ZBLAN 玻璃时应用磁场来减少晶体的形成。

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引用次数: 0

Tool chip contact length analysis of dry and cryogenic turning of aerospace alloy Ti-6Al-4V 航空航天合金 Ti-6Al-4V 干车削和低温车削的刀屑接触长度分析

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.083

Muhammad Ali Khan , Sachhal Mufti

Tool chip contact length is a vital machining index being representative of manufacturing efficiency. Various machining factors including tool wear and energy consumption are governed by tool chip contact length. The current work was undertaken to make a comparative analysis of dry and cryogenic turning of Ti-6Al-4V in terms of their sustainability and productivity indices. During experimentation, cutting speeds of 50 m/min and 125 m/min were selected working at feed rates ranging from 0.16 mm/rev to 0.24 mm/rev. Scanning electron microscopy was utilized to analyse the results. It was observed that machining under cryogenic conditions, in comparison with dry conditions, resulted in up to 51 % lower tool chip contact length. The results were also investigated in terms of chip formation for both machining environments. In addition, benefits of lower tool chip contact length were quantified in terms of lesser tool wear and better energy consumption. Tool chip contact length and chip formation analysis, indicative of the machining process efficiency, highlights that cryogenic condition is more sustainable and productive than dry conditions.

刀屑接触长度是一项重要的加工指标，代表着生产效率。包括刀具磨损和能耗在内的各种加工因素都受刀具切屑接触长度的影响。目前的工作是对 Ti-6Al-4V 的干车削和低温车削的可持续性和生产率指数进行比较分析。在实验过程中，选择了 50 米/分钟和 125 米/分钟的切削速度，进给率范围为 0.16 毫米/转到 0.24 毫米/转。利用扫描电子显微镜对结果进行分析。结果表明，在低温条件下加工与在干燥条件下加工相比，刀屑接触长度最多可减少 51%。此外，还对两种加工环境下的切屑形成情况进行了研究。此外，降低刀具切屑接触长度的好处还体现在减少刀具磨损和提高能耗方面。刀具切屑接触长度和切屑形成分析表明，低温条件比干燥条件更具可持续性和生产效率，这也是加工过程效率的体现。

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引用次数: 0

Hydrodynamic Flexible Spindle (HydroFlex) Polishing of turbine blade internal cooling channels for oxide removal 水动力柔性主轴 (HydroFlex) 研磨涡轮叶片内部冷却通道以去除氧化物

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.087

Jack Shanks , Patrick Chernjavsky , Rohit Dey , Yinggang Tian , Yihao Zheng

Internal cooling channels are essential to turbine blades for high efficiency power generation. Effective removal of aluminum oxide build-up in turbine blade cooling channels is of critical importance to refurbishment and prolonged service life of turbine blades. Conventional internal polishing processes, including abrasive flow machining, chemical polishing, and electrical discharge machining cannot effectively remove the oxide layer within the internal cooling channels due to the complex geometry with high aspect ratio and diameter variation and the electric insulation of the oxide layer. In this case study, we investigated the application of a novel hydrodynamic flexible-spindle (HydroFlex) polishing process to remove the oxide layer within the internal cooling channels of an Inconel 738 turbine blade that was taken out of serve due to oxide build-up. For a 350 mm long cooling channel featured with an inner diameter transition from ϕ4 mm to ϕ2.5 mm, within 12 min, at the grinding wheel rotational speed of 50,000 rpm and 30,000 rpm, HydroFlex was able to completely remove the 14.31 µm thick oxide layer off from the wall of the turbine blade internal cooling channel, improve the channel circularity by 54.7 %, and decrease the channel surface roughness by up to 64.3 %. The results demonstrated the effectiveness of HydroFlex in polishing complex internal cooling channels of turbine blades for oxide removal and potential blade service life extension.

内部冷却通道对于高效发电的涡轮叶片至关重要。有效清除涡轮叶片冷却通道中的氧化铝堆积物对于翻新和延长涡轮叶片的使用寿命至关重要。传统的内抛光工艺，包括磨料流加工、化学抛光和放电加工，都无法有效去除内冷却通道内的氧化层，原因是冷却通道的几何形状复杂，长径比和直径变化较大，而且氧化层具有电绝缘性。在本案例研究中，我们研究了应用新型流体动力柔性主轴（HydroFlex）抛光工艺去除因氧化物堆积而停用的 Inconel 738 涡轮叶片内部冷却通道内的氧化层。对于 350 毫米长、内径从ϕ4 毫米过渡到ϕ2.5 毫米的冷却通道，在砂轮转速分别为 50,000 转/分钟和 30,000 转/分钟的情况下，HydroFlex 能在 12 分钟内完全去除涡轮叶片内部冷却通道壁上 14.31 微米厚的氧化层，使通道圆度提高了 54.7%，通道表面粗糙度降低了 64.3%。结果表明，HydroFlex 能有效抛光涡轮叶片复杂的内部冷却通道，去除氧化物，并有可能延长叶片的使用寿命。

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引用次数: 0

Surface integrity analysis and inspection for nanochannel sidewalls using the self-affine fractal model-based statistical quality control for the atomic force microscopy (AFM)-based nanomachining process 基于原子力显微镜 (AFM) 的纳米机械加工过程中，使用基于自分形模型的统计质量控制对纳米通道侧壁进行表面完整性分析和检测

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.065

Xinchen Wang, Mohammad Alshoul, Jia Deng, Zimo Wang

The atomic force microscopy (AFM) technology is a promising method for nanofabrication due to the high tunability of this affordable platform. The quality inspection and control significantly impact the manufacturing effectiveness for realizing the functionality of the achieved nanochannel. Particularly, the surface characteristics of nanochannel sidewalls, which play a significant role in determining the quality of the nanomachined products, can not be accurately captured using conventional surface integrity metrics (e.g., surface roughness). Therefore, it is necessary to propose a method to quantitatively characterize the surface morphology and detect the abnormal parts/regions of the nanochannel sidewall. This paper presents a statistical process control approach derived from the self-affine fractal model to detect the sidewall surface anomalies. It evaluates changes in the self-affine fractal model parameters (standard deviation, correlation length, and roughness exponent), which can be used to signify the changes on the sidewall surface; the statistical distributions of these parameters are derived and used to develop control charts to allow inspection of the sidewall morphology. The approach was tested on the AFM-based nanomachined samples. The results suggest that the presented approach can effectively reflect the abnormal regions on the machined parts, which opens up a new avenue toward guiding the quality control and rework for process improvement for AFM-based nanomachining.

原子力显微镜（AFM）技术是一种很有前途的纳米制造方法，因为这种经济实惠的平台具有很高的可调性。质量检验和控制对实现纳米通道功能的制造效果有重大影响。尤其是纳米通道侧壁的表面特征，它在决定纳米机械产品的质量方面起着重要作用，但传统的表面完整性指标（如表面粗糙度）无法准确捕捉到纳米通道侧壁的表面特征。因此，有必要提出一种方法来定量表征表面形态并检测纳米通道侧壁的异常部分/区域。本文提出了一种源自自阿芬分形模型的统计过程控制方法，用于检测侧壁表面异常。它评估了自阿芬分形模型参数（标准偏差、相关长度和粗糙度指数）的变化，这些参数可用来表示侧壁表面的变化；得出了这些参数的统计分布，并用于开发控制图，以便对侧壁形态进行检测。该方法在基于原子力显微镜的纳米机械样品上进行了测试。结果表明，该方法能有效反映加工零件上的异常区域，为指导基于原子力显微镜的纳米机械加工的质量控制和返工工艺改进开辟了一条新途径。

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引用次数: 0

Investigation of experimental parameters in the electric field and mechanical vibration integrated AFM-based nanopatterning on PEDOT 基于原子力显微镜的 PEDOT 纳米图案化的电场和机械振动综合实验参数研究

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.070

Mohammad Alshoul, Xinchen Wang, Zimo Wang, Jia Deng

Atomic force microscope (AFM)-based nanomanufacturing offers an affordable and easily deployable method for fabricating high-resolution nanopatterns. This study employs a comprehensive design of experiment (DOE) approach to investigate the effects of various parameters, such as voltage, speed, and vibration axis, on the width and depth of lithography patterns using electrical field and vibration-assisted lithography on PEDOT: PSS films. The DOE explores the effect of voltage and speed on the process of electrical field and vibration-assisted AFM-based nanopatterning in two vibration trajectories: a circular trajectory employing X and Y axis vibration and a reciprocating trajectory employing Y axis vibration. The results indicate that using circular XY-vibration with a low stiffness contact probe and optimized speed and voltage factors results in higher depth and width of the lithography patterns compared to Y-vibration alone at the same parameters as expected. In both cases, pattern width was dominantly controlled by the voltage. Regarding depth, in XY-vibration, the speed of the tip is the most significant factor, while for Y-vibration, voltage plays the most significant role. It is noteworthy that there is a minimum threshold of speed that can produce a pattern; for example, the high-speed level that produced patterns in the circular trajectory (XY-vibration) did not produce patterns in reciprocating motion (Y-vibration). In conclusion, the study demonstrates the significant impact of voltage, speed, and axis on the width and depth of the lithography patterns. These findings can be instrumental in developing and understanding AFM-based high-resolution nanofabrication techniques.

基于原子力显微镜（AFM）的纳米制造为制造高分辨率纳米图案提供了一种经济实惠、易于部署的方法。本研究采用综合实验设计（DOE）方法，利用电场和振动辅助光刻技术在 PEDOT.PSS 薄膜上研究电压、速度和振动轴等各种参数对光刻图案宽度和深度的影响：PSS 薄膜上光刻图案的宽度和深度的影响。DOE 探讨了电压和速度对基于电场和振动辅助 AFM 的两种振动轨迹的纳米图案刻制过程的影响：一种是采用 X 和 Y 轴振动的圆形轨迹，另一种是采用 Y 轴振动的往复式轨迹。结果表明，在参数相同的情况下，使用带有低刚度接触探针的圆形 XY 轴振动以及优化的速度和电压系数，与单独使用 Y 轴振动相比，光刻图案的深度和宽度更高。在这两种情况下，图案宽度主要由电压控制。关于深度，在 XY 振荡中，针尖的速度是最重要的因素，而对于 Y 振荡，电压则起着最重要的作用。值得注意的是，产生图案的速度有一个最低阈值；例如，在圆形轨迹（XY-振动）中产生图案的高速水平在往复运动（Y-振动）中并不产生图案。总之，这项研究证明了电压、速度和轴对光刻图案宽度和深度的重要影响。这些发现有助于开发和理解基于原子力显微镜的高分辨率纳米制造技术。

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引用次数: 0

Electrochemical additive manufacturing of interdigitated structures using a multi-anode system with independently-controlled anodes 使用具有独立控制阳极的多阳极系统电化学增材制造互嵌结构

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.048

Anne Brant, Spencer Keane, Murali Sundaram

Interdigitated parts are used across a multitude of engineering applications. The overlapping, intertwined structures pose a challenge for fabrication using conventional additive manufacturing techniques, especially at small size scales. Electrochemical additive manufacturing (ECAM) has been shown to successfully create overhanging parts at the small scale without reliance on support structures. This study extends the ECAM capabilities into demonstration of the fabrication of interdigitated parts by the use of a multi-anode electrochemical additive manufacturing system. The ECAM process is operated by a tool head consisting of multiple anodes independently controlled by individual channels on an in-house-built multipotentiostatic system. Each anode is independently switched into active (anodic) or inactive (open-circuit) mode using a predefined, coded pattern controlling the custom electronics. While each tool is in anodic mode, its current contribution into the overall deposition process is tracked independently as well. Each independent tool can deposit material extending from regions deposited by itself or neighboring tools. The entire multi-head tool is controllably moved by a 3-axis translation system. An interdigitated comb geometry relevant to practical engineering applications is fabricated using this system. This geometry is built using a parallelized voxel-by-voxel tool path with characteristic electrode activation patterns at each position of the tool head. It was found that a purely closed-loop control with no time limit yielded a qualitatively better geometry than a control system with a 10-minute time limit applied. This study overall demonstrates the working principle of a multi-anode system and its ability to fabricate parts interdigitated structures. This study therefore advances the capabilities of ECAM as a valuable additive manufacturing process that can fabricate a variety of challenging parts for relevant engineering applications.

交织部件广泛应用于各种工程领域。重叠、交织的结构给使用传统增材制造技术进行制造带来了挑战，尤其是在小尺寸范围内。电化学增材制造（ECAM）已被证明能成功制造出小尺寸的悬挂部件，而无需依赖支撑结构。本研究通过使用多阳极电化学快速成型制造系统，将电化学快速成型制造技术的功能扩展到制造相互咬合的零件。ECAM 工艺由一个工具头操作，工具头由多个阳极组成，这些阳极由内部制造的多电位静电系统上的单通道独立控制。每个阳极都可通过控制定制电子元件的预定义编码模式独立切换到活动（阳极）或非活动（开路）模式。当每个工具处于阳极模式时，其对整个沉积过程的电流贡献也会被独立跟踪。每个独立的工具都可以沉积从自身或相邻工具沉积区域延伸出来的材料。整个多头工具由一个三轴平移系统控制移动。利用该系统可以制造出与实际工程应用相关的互咬梳几何形状。该几何图形采用逐体素并行工具路径，在工具头的每个位置都具有特征电极激活模式。研究发现，与采用 10 分钟时间限制的控制系统相比，无时间限制的纯闭环控制所生成的几何体质量更好。这项研究从总体上展示了多阳极系统的工作原理及其制造部件相互咬合结构的能力。因此，本研究推进了 ECAM 作为一种有价值的增材制造工艺的能力，它可以为相关工程应用制造各种具有挑战性的零件。

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引用次数: 0