Manufacturing Letters最新文献_第10页

Iterative correction of robotic grinding using spatial feedback for precision applications 利用空间反馈对机器人打磨进行迭代修正，以实现精确应用

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.031

Philip A. Olubodun, Joseph D. Fischer, Douglas A. Bristow

Since the advent of robots, many tasks that were originally performed by humans have now been tasked to industrial robots. From a manufacturing standpoint, robots have primarily been used in pick-and-place or other non-machining operations that require high repeatability. However, with the increasing availability of CAD/CAM software and the development of high-precision metrology, comes the opportunity to integrate robots into a wider variety of manufacturing processes through the use of feedback control. One such machining operation that is being explored is precision grinding of metal parts. Most other work in this area has focused on force regulation to improve grind quality; however, this paper takes a different approach. In this work, an Iterative Learning Control (ILC) algorithm is implemented to correct the geometric error directly by altering the toolpath trajectory. Specifically, in this framework, a conservative initial cutting trajectory is implemented using a 6-DoF robotic grinding system, and the resulting part geometry is measured via a high-precision laser scanner. Based on the resultant geometric error, the toolpath is corrected and then rerun on the part. This process is then repeated iteratively until sufficient accuracy is achieved. Due to the inability to replace material in overground regions, the controller is designed with an emphasis on reducing overshoot which cannot be corrected. The controller is experimentally validated by grinding an elliptical pocket which meets FAA specifications for corrosion removal in aircraft. The results showed that within seven iterations the entire error surface could be brought to a tolerance of ±0.150 mm for the given geometry.

自从机器人问世以来，许多原本由人类完成的任务现在都交给了工业机器人。从制造的角度来看，机器人主要用于拾放或其他需要高重复性的非加工操作。然而，随着 CAD/CAM 软件的日益普及和高精度计量学的发展，机器人有机会通过使用反馈控制，集成到更广泛的制造流程中。目前正在探索的一种加工操作是金属零件的精密打磨。该领域的大多数其他工作都侧重于力的调节，以提高打磨质量；但本文采用了不同的方法。本文采用迭代学习控制 (ILC) 算法，通过改变刀具轨迹直接修正几何误差。具体来说，在此框架下，使用 6-DoF 机器人磨削系统实现保守的初始切削轨迹，并通过高精度激光扫描仪测量由此产生的零件几何形状。根据由此产生的几何误差，对刀具轨迹进行修正，然后在零件上重新运行。这一过程反复进行，直到达到足够的精度。由于无法替换过磨区域的材料，控制器的设计重点是减少无法修正的过冲。该控制器通过磨削符合美国联邦航空局飞机除锈规范的椭圆形凹槽进行了实验验证。结果表明，对于给定的几何形状，在七次迭代中，整个误差面的公差可达到 ±0.150 毫米。

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引用次数: 0

Influence of milling interventions on the geometry of wall-shaped structures in hybrid wire-arc direct energy deposition 混合线弧直接能量沉积中铣削干预对壁状结构几何形状的影响

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.096

Akshar Kota, Shohom Bose-Bandyopadhyay, Asif Rashid, Shreyes N. Melkote

The Hybrid Wire-Arc Direct Energy Deposition (Hybrid Wire-Arc DED) process integrates Wire-Arc Direct Energy Deposition (Wire-Arc DED) with machining (typically milling) interventions, offering the potential for creating intricate geometries and finished surfaces. However, if milling is employed as a hybrid intervention rather than as a final part-finishing process, the interplay between these processes remains under-investigated. This paper examines the influence of milling interventions on the geometry of a wall-shaped structure, quantified by the transverse cross-sectional width, built using a Hybrid Wire-Arc DED. Through experiments on mild steel, the underlying causes of observed wall-width variations are analyzed. Initial observations suggested that thermo-mechanical deformations from milling influence the width variations. However, evidence indicates the significant role of additional remelting cycles experienced by the milled surface layer during subsequent layer depositions. The study also reveals that the observed increase in wall width for each milling intervention occurs at approximately the same depth below the milled surface. A mechanistic explanation for this observation is given. Crucially, the findings suggest that unless milling is done at higher frequencies, like after each layer deposition, the resultant unevenness might render the Hybrid Wire-Arc DED process less efficient in terms of surface quality and dimensional accuracy than its non-hybrid counterpart.

线-弧混合直接能量沉积（Hybrid Wire-Arc DED）工艺将线-弧直接能量沉积（Wire-Arc DED）与机加工（通常是铣削）干预集成在一起，为创造复杂的几何形状和精加工表面提供了可能性。然而，如果将铣削作为一种混合干预而不是作为最终的零件精加工工艺来使用，那么这些工艺之间的相互作用仍未得到充分研究。本文研究了铣削干预对墙形结构几何形状的影响，该几何形状由横向截面宽度量化，使用混合线弧钻铣制造。通过对低碳钢的实验，分析了观察到的壁宽变化的根本原因。初步观察表明，铣削产生的热机械变形影响了宽度变化。然而，有证据表明，铣削表面层在后续层沉积过程中经历的额外重熔循环起了重要作用。研究还发现，每次铣削过程中观察到的壁宽增加都发生在铣削表面以下大致相同的深度。研究给出了这一观察结果的机理解释。最重要的是，研究结果表明，除非以更高的频率进行铣削，例如在每层沉积后进行铣削，否则由此产生的不平整可能会使混合线-电弧 DED 工艺在表面质量和尺寸精度方面的效率低于非混合工艺。

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引用次数: 0

SLM-printed lattice structures with tapered vertical struts: Design, simulation and experimentation 带有锥形垂直支柱的 SLM 印刷晶格结构：设计、模拟和实验

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.100

Daniyar Syrlybayev, Andrei Yankin, Asma Perveen, Didier Talamona

This study, designed new lattice structures using vertical struts that taper off. The degree of tapering was controlled using a parameter called “α”. To fabricate these structures, 3D-printing technology known as SLM (selected laser melting) was used. These lattice structures were also simulated using finite element analysis (FEA) and tested experimentally. The used material was 316L stainless steel. Stress–strain curves provided insights into their deformation behavior, revealing a noteworthy occurrence: the unloading modulus exceeded the loading modulus. The mechanical properties of these absolute and density-normalized lattice structures, demonstrated improvement with higher values of the shape parameter α. Yield stress increased by 31 %, loading modulus by 21 %, and energy absorption by 33 %. Specific yield stress improved by 24 %, and specific energy absorption increased by 27 %. While simulation and experimental results exhibited a correlation, they differed significantly in modulus estimation, with simulations overestimating it by more than 30 %.

这项研究利用逐渐变细的垂直支柱设计了新的晶格结构。锥度由一个名为 "α "的参数控制。为了制造这些结构，使用了被称为 SLM（选择性激光熔融）的 3D 打印技术。还使用有限元分析（FEA）对这些晶格结构进行了模拟，并进行了实验测试。所用材料为 316L 不锈钢。应力-应变曲线揭示了它们的变形行为，并发现了一个值得注意的现象：卸载模量超过了加载模量。这些绝对和密度归一化晶格结构的机械性能随着形状参数 α 值的提高而得到改善，屈服应力提高了 31%，加载模量提高了 21%，能量吸收提高了 33%。比屈服应力提高了 24%，比能量吸收提高了 27%。虽然模拟和实验结果显示出相关性，但在模量估计方面却存在显著差异，模拟结果高估了 30% 以上。

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引用次数: 0

Applying design complexity metrics for post-processing cost modeling in metal additive manufacturing 在金属增材制造中应用设计复杂性指标进行后处理成本建模

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.098

Riccardo C. Clemente, Seyed A. Niknam

The recent Additive manufacturing (AM) literature has primarily concentrated on exploring new avenues for improving the current technology and its applicability. It has also delved into research investments aimed at addressing the last remaining prediction challenges associated with current AM processes, particularly focusing to surface quality, accuracy, and internal composition. These limitations can often be mitigated though the application of post-processing techniques. Such techniques are often very costly both in time and monetary terms.

When it comes to the impact that shape complexity has on post-fabrication costs for AM parts, a gap in the literature is apparent. In recent years, more attention has been devoted to researching a general shape complexity metric. It has been suggested in the literature to combine multiple of complexity metrics techniques, to reach more comprehensive model. This aspect has not received enough attention in previous works. In addition, the relationship between shape complexity and post-processing costs has not been assessed. And there are no predictive models for post-processing costs based on complexity.

In this study, AM shapes for prototyping application are analysed. In this regard, previously established complexity metrics are used, together with expert’s assessments of post-processing costs, to create a model capable of predicting post-processing costs. This is achieved through a regression analysis using costs and complexity metrics values. The result of this research are two regression models, named 7 V and Vol/Sur Models, capable of predicting post-processing costs for AM parts produced through DMLS techniques with SS316L stainless steel powder. The accuracy of the two models is discussed.

近期的增材制造（AM）文献主要集中在探索改进当前技术及其适用性的新途径。此外，还深入开展研究投资，旨在解决与当前增材制造工艺相关的最后遗留的预测难题，尤其侧重于表面质量、精度和内部组成。这些限制通常可以通过应用后处理技术来缓解。当谈到形状复杂性对 AM 零件后加工成本的影响时，文献中的空白是显而易见的。近年来，越来越多的人开始关注通用形状复杂性指标的研究。有文献建议结合多种复杂度度量技术，以建立更全面的模型。在以往的研究中，这方面还没有得到足够的重视。此外，形状复杂度与后处理成本之间的关系也没有得到评估。本研究分析了用于原型制作的 AM 形状。在这方面，使用了之前建立的复杂性指标，并结合专家对后处理成本的评估，创建了一个能够预测后处理成本的模型。这是通过使用成本和复杂性指标值进行回归分析实现的。这项研究的成果是两个回归模型，分别命名为 7 V 和 Vol/Sur 模型，能够预测使用 SS316L 不锈钢粉末通过 DMLS 技术生产的 AM 零件的后处理成本。本文讨论了这两个模型的准确性。

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引用次数: 0

A critical assessment of the onset strain of densification in the evaluation of energy absorption for additively manufactured cellular materials 在评估增材制造蜂窝材料的能量吸收时对致密化起始应变进行严格评估

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.089

Mandar Shinde, Irving E. Ramirez-Chavez, Alexander Potts, Dhruv Bhate

Densification strain is an essential parameter in the characterization of energy absorption of additively manufactured cellular structures. In addition to its own merits as a metric that indicates usable stroke length for energy absorbers, it is central to the computation of energy absorbed by the structure. However, at least four different approaches have been used in the literature, each with its own limitations. In this work, a critical review of these approaches is first presented. While the maximum efficiency approach has been demonstrated to be optimal for cellular foams, this work shows how, for some additively manufactured cellular materials, it can fail to estimate densification strain accurately due to its sensitivity to instantaneous stress values in the plateau region. An alternative method is proposed in this work that leverages peak stress instead to determine the onset strain of densification and is shown to be consistently accurate across a range of cellular materials. The method is validated with the results from an experimental study of energy absorption in six different types of cellular structures across three relative densities, with identical geometries fabricated in two different base materials and processes: AlSi10Mg with Laser Powder Bed Fusion, and Nylon-12 with Selective Laser Sintering.

致密化应变是表征加成制造蜂窝结构能量吸收的一个重要参数。除了作为表示能量吸收器可用冲程长度的指标本身的优点外，它还是计算结构能量吸收的核心。然而，文献中至少使用了四种不同的方法，每种方法都有其自身的局限性。在这项工作中，首先对这些方法进行了严格审查。虽然最大效率法已被证明是蜂窝泡沫的最佳方法，但本研究表明，对于某些添加制造的蜂窝材料，由于其对高原区瞬时应力值的敏感性，该方法可能无法准确估计致密化应变。本研究提出了一种替代方法，利用峰值应力来确定致密化的起始应变，结果表明该方法在一系列蜂窝材料中始终保持精确。该方法通过对三种相对密度的六种不同类型蜂窝结构的能量吸收实验研究结果进行了验证，这些蜂窝结构采用两种不同的基体材料和工艺制造而成，具有相同的几何形状：采用激光粉末床熔融技术的 AlSi10Mg 和采用选择性激光烧结技术的尼龙-12。

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引用次数: 0

Plasmonic image reproduction with solid-state superionic stamping (S4) 利用固态超离子冲压技术再现等离子图像 (S4)

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.073

Boqiang Qian, Papia Sultana, Ricardo Toro, Glennys Mensing, Placid Ferreira

Traditional top-down approaches for producing metallic nanostructures, despite being capable of producing arbitrary 2-D shapes, often use vacuum-based deep sub-micron lithographic fabrication technologies. This makes their use for single-use devices like chemical and bio-sensing substrates difficult to economically justify. Here, the authors demonstrate a manufacturing pathway that only uses such techniques to produce a master. This reusable master, coupled with a unique and facile electrochemical imprinting process, Solid-State Superionic Stamping (S4), is used to produce several replicated metallic nanostructures, thus demonstrating an economically feasible manufacturing pathway for single-use, nano-enabled devices.

This paper uses plasmonic image reproduction as an easy-to-visualize proxy for single-use devices such as plasmonic sensors and Surface Enhanced Raman Spectroscopy (SERS) substrates that require nanopatterned metallic structures. It demonstrates a process for replicating a picture by a set of metallic structures that plasmonically produce the desired colors locally. It uses a digitizing computational tool, direct-write Two-Photon Lithography (TPL) and a dry-etch process to rapidly produce a silicon master. This master is used to hot emboss nano-patterns in superionic glass blanks that, in turn, are used for electrochemical imprinting with S4 to reproduce the patterns on Ag substrates. The different steps in this process flow are described along with their role and effectiveness in contributing to a high-fidelity plasmonic image reproduction.

生产金属纳米结构的传统自上而下方法尽管能够生产任意的二维形状，但通常使用真空深亚微米光刻制造技术。这就使得将其用于化学和生物传感基底等一次性设备在经济上难以成立。在此，作者展示了一种仅使用此类技术生产母版的制造途径。这种可重复使用的母版与独特而简便的电化学压印工艺--固态超负离子冲压（S4）--相结合，可用于生产多种复制的金属纳米结构，从而为一次性使用的纳米设备展示了一种经济可行的制造途径。本文将等离子图像复制作为一次性使用设备（如等离子传感器和表面增强拉曼光谱（SERS）基底）的一种易于可视化的代理方法，这些设备需要纳米图案化的金属结构。它展示了通过一组金属结构复制图片的过程，这些金属结构能在局部产生所需的颜色。它使用数字化计算工具、直接写入双光子光刻技术（TPL）和干蚀刻工艺来快速制作硅母版。该母版用于在超离子玻璃坯上热压印纳米图案，然后用 S4 进行电化学压印，在银基板上复制图案。本文介绍了这一工艺流程中的不同步骤，以及它们在高保真等离子图像再现中的作用和效果。

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引用次数: 0

Nanotechnology-enabled rapid investment casting of high-performance wrought aluminum alloys 利用纳米技术快速投资铸造高性能锻造铝合金

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.040

Yitian Chi , Xiaochun Li

High-performance wrought aluminium alloys are widely used in automobiles and aerospace industries owing to their high-volume precipitates after heat treatment. Investment casting as one of the precision manufacturing methods provides great potential to achieve excellent surface finishes and complex geometry for aluminium alloy components. However, these high-performance aluminium alloys are almost impossible to be investment cast due to their hot cracking susceptibility and severe shrinkage during solidification. In this study, we introduce nanotechnology to improve the processability of high-performance wrought aluminium alloys in investment casting by adding a small volume fraction of nanoparticles into the aluminium alloys. This work showed the unprecedented success of nanotechnology-enabled investment casting of high-strength wrought aluminium alloys (AA6061, AA2024, and AA7075) for excellent mechanical properties.

高性能锻造铝合金在热处理后会产生大量析出物，因此被广泛应用于汽车和航空航天工业。熔模铸造作为精密制造方法之一，为铝合金部件实现出色的表面光洁度和复杂的几何形状提供了巨大的潜力。然而，由于这些高性能铝合金在凝固过程中易产生热裂纹和严重收缩，因此几乎无法进行熔模铸造。在这项研究中，我们引入了纳米技术，通过在铝合金中添加小体积分数的纳米颗粒，来改善高性能锻造铝合金在熔模铸造中的加工性。这项工作表明，利用纳米技术进行高强度锻造铝合金（AA6061、AA2024 和 AA7075）的熔模铸造取得了前所未有的成功，并获得了优异的机械性能。

引用次数: 0

History of NAMRI and NAMRC 纳米比亚自然资源研究所和纳米比亚自然资源研究中心的历史

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.002

引用次数: 0

Milling infiltrated carbon-bonded carbon fiber: Geometric attributes, surface characteristics, and feasibility 铣削浸润碳结合碳纤维：几何属性、表面特征和可行性

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.051

Jake Dvorak , Dustin Gilmer , Ross Zameroski , Tony Schmitz

This paper describes a manufacturing approach for carbon-bonded carbon fiber where cyanoacrylate and wax infiltration are used to improve the handling and machinability of preforms. Structured light optical coordinate metrology is used to acquire a stock model for computer-aided manufacturing and work coordinate system definition for machining. Non-infiltrated (neat) and infiltrated samples are machined using the same part program to compare results. Geometric attributes are measured with a touch trigger probe coordinate measuring machine and surface characteristics are measured with an optical 3D measuring system. Experimental results show superior geometric accuracy and surface roughness for the infiltrated samples over the neat sample.

本文介绍了一种碳键合碳纤维的制造方法，该方法使用氰基丙烯酸酯和蜡浸润来改善预型件的处理和可加工性。结构光光学坐标测量法用于获取用于计算机辅助制造和加工工件坐标系定义的毛坯模型。使用相同的零件程序对未浸润（纯净）和浸润样品进行加工，以比较结果。几何属性用触发式测头坐标测量机测量，表面特征用光学 3D 测量系统测量。实验结果表明，浸润样品的几何精度和表面粗糙度均优于未浸润样品。

引用次数: 0

Prediction of automotive body-in-white distortion in paint baking process 汽车白车身在烤漆过程中的变形预测

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.032

Wayne Cai, Matthew Bondy, Blair Carlson, Mark Baylis

Thermal-induced distortion prediction of thin shell structures is a challenging task. It often involves highly nonlinear buckling behaviour, where the critical buckling temperature and post-buckling deformations are very sensitive not only to structural stiffness and boundary conditions but also minute geometric imperfections (a.k.a., “surface quality”) of the incoming parts. In the present work, novel Computer Aided Engineering (CAE) methods were developed to predict the thermal-induced distortion of automotive Body-in-White (BIW) panels during paint shop oven-baking processes. The CAE methodology consist of a set of three Finite Element Analysis (FEA) procedures, i.e., thermal-buckling mode analysis, thermo-structural analysis, and imperfection analysis. Two vehicle level case studies showed that simulations successfully predicted the thermal-induced distortion for panels such as the Body Side Outer (BSO) header. It was concluded that the distortion depends primarily on the temperature difference between the BSO and the rest of the BIW during the oven-baking process, rather than the temperatures themselves. Body panel forming quality (e.g., residual stresses and thickness thinning) and assembly dimensional quality were also found to impact the distortions.

薄壳结构的热诱导变形预测是一项具有挑战性的任务。它通常涉及高度非线性屈曲行为，其中临界屈曲温度和屈曲后变形不仅对结构刚度和边界条件非常敏感，而且对输入部件的微小几何缺陷（又称 "表面质量"）也非常敏感。本研究开发了新型计算机辅助工程（CAE）方法，用于预测汽车白车身（BIW）面板在涂装车间烘烤过程中的热变形。CAE 方法包括三套有限元分析（FEA）程序，即热褶皱模式分析、热结构分析和缺陷分析。两项车辆级案例研究表明，模拟成功地预测了车身侧外侧（BSO）顶盖等面板的热诱导变形。得出的结论是，变形主要取决于烘箱烘烤过程中车身侧外板与车身侧外板其余部分之间的温差，而不是温度本身。研究还发现，车身面板成型质量（如残余应力和厚度减薄）和装配尺寸质量也会影响变形。

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引用次数: 0