Manufacturing Letters最新文献_第3页

Unsupervised detection and mapping of sparks in the Electrochemical Discharge Machining (ECDM) process 电化学放电加工 (ECDM) 过程中火花的无监督检测和映射

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.052

Prayag Gore, Yu-Jen Chen, Murali Sundaram

Material removal in electrochemical discharge machining is caused by sparks generated in a tool immersed in an electrolytic solution. Being the primary machining agent in this non-contact machining process, mapping the locations of microscopic sparks is of great interest. The distribution of sparks around the tool surface could give insights into the machined hole properties like the size, surface finish, and depth as compared to the machining parameters such as applied voltage, tool size, rotation speed, and feed rate. This paper is focused on detecting sparks in photographs of the ECDM process captured using a high-speed camera. A novel approach of using a tri-planar reflective surface for capturing the location of sparks in 3D space using a 2D camera output is attempted. Traditional spark detection methods use neural network classifiers that need labeled data for training. This labeled data often comes from human intervention and contains inherent biases that could lead to misclassification. In this paper, an unsupervised spark detection methodology is demonstrated, which eliminates the need for human intervention and relies on the number of neighboring pixels detected in regions of interest (ROIs). The feasibility of using adaptive background modeling to classify thousands of images and identify the ones with sparks is demonstrated in this work. The masking technique combining effects of erosion followed by dilation is used to determine the exact boundaries of the spark contours in every image. Centroids for each of these contours are then transformed from the skewed coordinate system as observed in camera images, to a three-dimensional orthogonal coordinates system centered around the tool. The same procedure is repeated for various voltages to benchmark the distribution of sparks around a tool tip in an ECDM process.

电化学放电加工中的材料去除是由浸泡在电解溶液中的工具产生的火花引起的。作为这种非接触式加工过程中的主要加工剂，绘制微观火花位置图具有重大意义。与加工参数（如外加电压、刀具尺寸、旋转速度和进给速度）相比，刀具表面周围的火花分布可以让人深入了解加工孔的特性，如尺寸、表面光洁度和深度。本文的重点是在使用高速相机拍摄的 ECDM 过程照片中检测火花。本文尝试了一种新方法，即使用三平面反射面，利用二维相机输出捕捉三维空间中的火花位置。传统的火花检测方法使用神经网络分类器，需要标注数据进行训练。这些标注数据通常来自人工干预，并包含可能导致误分类的固有偏差。本文展示了一种无监督火花检测方法，该方法无需人工干预，而是依赖于感兴趣区域（ROI）中检测到的相邻像素数量。这项工作证明了使用自适应背景建模对数千张图像进行分类并识别出带有火花的图像的可行性。在每幅图像中，我们使用了结合侵蚀和扩张效果的遮蔽技术来确定火花轮廓的准确边界。然后将每个轮廓的中心点从相机图像中观察到的倾斜坐标系转换为以工具为中心的三维正交坐标系。在 ECDM 过程中，对不同的电压重复同样的过程，以确定刀尖周围火花的分布情况。

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引用次数: 0

Design of thermomechanical processes for tailored microstructures 设计用于定制微结构的热机械工艺

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.050

Lukas Kluy , Lina Klinge , Christopher Spiegel , Carsten Siemers , Peter Groche

Thermomechanical processes enable tailoring of material properties and microstructures for advanced products. In medical technology, next-generation titanium implants require tailored material properties to improve health and quality of life. However, the interaction correlation between process parameters and material properties poses a major challenge for the design of thermomechanical manufacturing processes.

In this paper, we present a methodology for the design of thermomechanical processes to achieve tailored microstructural properties through forming technology and heat treatments. The methodology consists of five systematic steps to address the complexity of multiphysical coupling relationships between temperature, stress, microstructure and alloy composition, and to provide a guideline for effective implementation. It is applied to the production of nanostructured Ti-13Nb-13Zr (NanoTNZ) alloy for dental implants. The designed process of severe plastic deformation, recrystallization treatment and aging lead to nanostructured microstructures smaller than 200 nm. The resulting mechanical properties (UTS > 980 MPa, Young’s modulus of 73 GPa) meet the desired goals for improved biomedical implant-bone interactions. The tailored material properties and microstructures of NanoTNZ are therefore highly promising for use as an implant material.

The case study demonstrates the importance of a systematic method to manage the complexity of multiphysical coupling relationships in the design of thermomechanical processes to enable tailored microstructures for advanced materials and products.

热机械工艺可为先进产品量身定制材料特性和微结构。在医疗技术领域，下一代钛植入物需要量身定制的材料特性，以改善健康和生活质量。然而，工艺参数与材料特性之间的相互作用关系对热机械制造工艺的设计构成了重大挑战。本文介绍了一种热机械工艺设计方法，通过成型技术和热处理实现量身定制的微观结构特性。该方法包括五个系统步骤，以解决温度、应力、微观结构和合金成分之间复杂的多物理耦合关系，并为有效实施提供指导。该方法被应用于生产用于牙科植入物的纳米结构 Ti-13Nb-13Zr (NanoTNZ) 合金。通过设计的剧烈塑性变形、再结晶处理和老化过程，形成了小于 200 nm 的纳米微结构。由此产生的机械性能（UTS > 980 MPa，杨氏模量 73 GPa）达到了改善生物医学植入物与骨相互作用的预期目标。该案例研究表明，在设计热机械过程时，必须采用系统的方法来管理多物理耦合关系的复杂性，从而为先进材料和产品量身定制微结构。

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引用次数: 0

Mass customization using hybrid manufacturing and smart assembly: An optimal configuration and platform design approach 利用混合制造和智能装配实现大规模定制：优化配置和平台设计方法

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.016

Hany Osman , Ahmed Azab , Rifat Bin Hasan , Fazle Baki

Hybrid Manufacturing (HM) and smart assembly stand as pivotal pillars in advanced smart manufacturing systems, offering manufacturers highly efficient and adaptable solutions for manufacturing. This paper delves into the configuration of a production line that integrates HM and assembly stages, each comprising multiple cells, with each cell housing one or more parallel stations. The objective is to manufacture a family of final assemblies, leveraging the platform concept to defer mass customization to later stages and thereby minimize processing costs. A mathematical programming model is proposed to identify the optimal configuration for such production lines, considering constraints such as an allowable capital cost and machine availabilities. In addition, the precedence, inclusion, and seclusion restrictions imposed on the part family are considered. The proposed mathematical programming model aims to delineate which HM features are processed in the part platform cell versus those processed in the mass customization (part variants) cells. Simultaneously, the model determines the components (variants from the HM stage) of final assemblies processed in the assembly platform cell, as well as components assembled or disassembled in the final assembly cells. Furthermore, the model seeks to determine the required number of stations in each cell to meet periodic demand. The overall objective of the model is to minimize the capital and the processing cost. A detailed case study illustrates the effectiveness of the proposed configuration approach and mathematical model. The proposed model is solvable in a few seconds by using commercial solvers.

混合制造（HM）和智能装配是先进智能制造系统的重要支柱，可为制造商提供高效、适应性强的制造解决方案。本文深入探讨了生产线的配置，该生产线集成了混合制造和装配阶段，每个阶段由多个单元组成，每个单元包含一个或多个并行工位。目标是利用平台概念，将大规模定制推迟到后期阶段，从而最大限度地降低加工成本，制造出一系列最终组件。考虑到可允许的资本成本和机器可用性等约束条件，我们提出了一个数学编程模型，以确定此类生产线的最佳配置。此外，还考虑了对零件系列施加的优先级、包含和隔离限制。所提出的数学编程模型旨在划定哪些 HM 特征在零件平台单元中处理，哪些在大规模定制（零件变体）单元中处理。同时，该模型还能确定在装配平台单元中加工的最终装配组件（HM 阶段的变体），以及在最终装配单元中装配或拆卸的组件。此外，该模型还能确定每个单元所需的工位数量，以满足周期性需求。该模型的总体目标是最大限度地降低资本和加工成本。一个详细的案例研究说明了建议的配置方法和数学模型的有效性。通过使用商业求解器，建议的模型可在几秒钟内求解。

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引用次数: 0

Clinical-relevant sized tubular capillary mimicries by sacrificial core-sheath electrospinning 通过牺牲芯鞘电纺丝技术制造临床相关尺寸的管状毛细管仿制品

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.056

Yan Chen, Yingge Zhou

Electrospinning is a versatile technique that is often used to fabricate ultra-fine fibers. With the help of a coaxial spinneret, microtubes can be fabricated as potential biomimetic capillary vessels. However, the sizes of electrospun microtubes in recent research were around 5 μm which is smaller to native capillary vessels (5–10 μm). The electrospun microtube diameter can be determined by various electrospinning parameters such as spinning materials, solvent, spinning distance, solution pump rate, applied voltage, etc. In this research, we explored the effects of spinning distance and core/sheath pump rate ratio on microtube diameter and wall thickness. Viscosity, wettability, and tensile tests were also conducted for microtube characterization. The results indicated that the microtube diameters range from 5 μm to 12 μm, which provides a promising direction for the fabrication of biomimetic capillary vessels.

电纺丝是一种多功能技术，通常用于制造超细纤维。在同轴喷丝板的帮助下，微管可被制造成潜在的仿生物毛细血管。不过，近期研究中电纺微管的尺寸约为 5 μm，小于原生毛细血管（5-10 μm）。电纺微管的直径可由各种电纺参数决定，如纺丝材料、溶剂、纺丝距离、溶液泵速、施加电压等。本研究探讨了纺丝距离和芯/鞘泵率比对微管直径和壁厚的影响。此外，还进行了粘度、润湿性和拉伸测试，以确定微管的特性。结果表明，微管直径在 5 μm 至 12 μm 之间，这为制造仿生物毛细管容器提供了一个很好的方向。

引用次数: 0

Effect of drying temperature on binder/current collector interfacial adhesion in electrode manufacturing of Li-ion batteries 干燥温度对锂离子电池电极制造中粘合剂/集流体界面粘附力的影响

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.036

Xiaowei Yu , Mengyuan Chen , Ming Wang , Jennifer Bracey , Bradley Frieberg , Roland Koestner , Wai Ping Gloria Tam , David Titmuss , Nicholas Ware

Li-ion battery manufacturing process parameters are critical to the electrode properties and the final cell electrochemical performance. During the electrode drying process, the drying temperature plays a critical role on the binder migration, which affects the interfacial adhesion between the electrode and the current collector. However, the influence of the temperature on the properties of the binder material and the binder/current collector interface is yet unknown. In this work, we studied the effect of drying temperature on the interfacial adhesion between the binder and the current collector by direct coating of polyvinylidene fluoride (PVDF) solution on Al foil and then drying at various temperatures. The interfacial adhesion strength between the PVDF and the Al foil was significantly increased, from 9.72 N/m (dried at room temperature) to > 665.80 N/m (dried at 200 ℃) with increased temperature. DSC and XRD analyses showed the changes in the crystalline forms of PVDF under different drying temperature. This work revealed that the drying temperature during electrode manufacturing should be considered from the aspects of both binder migration in mid-stage and PVDF crystalline properties in late-stage solvent drying.

锂离子电池制造工艺参数对电极特性和最终电池的电化学性能至关重要。在电极干燥过程中，干燥温度对粘结剂的迁移起着至关重要的作用，而粘结剂的迁移会影响电极与集流体之间的界面粘附力。然而，温度对粘结剂材料和粘结剂/集流器界面性能的影响尚不清楚。在这项工作中，我们通过在铝箔上直接涂覆聚偏二氟乙烯（PVDF）溶液，然后在不同温度下干燥，研究了干燥温度对粘合剂和集流器之间界面粘附力的影响。随着温度的升高，聚偏二氟乙烯（PVDF）与铝箔之间的界面粘附强度显著增加，从 9.72 N/m（室温下干燥）增加到 > 665.80 N/m（200 ℃ 下干燥）。DSC 和 XRD 分析表明了不同干燥温度下 PVDF 晶体形态的变化。这项工作揭示了电极制造过程中的干燥温度应从中期粘合剂迁移和后期溶剂干燥时的 PVDF 结晶特性两方面加以考虑。

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引用次数: 0

Investigations on ironing parameters in screw extrusion additive manufacturing (SEAM) 螺杆挤出增材制造（SEAM）中的熨烫参数研究

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.102

Yash Gopal Mittal , Gopal Gote , Yogesh Patil , Avinash Kumar Mehta , Pushkar Kamble , K.P. Karunakaran

Additive Manufacturing (AM) is a novel manufacturing process that enables the physical realization of a given 3D model via layered deposition. Material extrusion (MEX) is one of the most widely used forms of the various AM techniques, in which the screw extrusion-based AM (SEAM) processing offers the most versatile characteristics, in terms of material handling and flow rate capacities. It involves continuous extrusion of the semi-solid material via an extruder screw. Ironing is a common practice in MEX techniques, to maintain z-height and improve the surface morphologies while deposition. Most commercially used nozzles for MEX are thin-walled, such that the ratio of the nozzle width to the diameter (w/d) is close to 1. In this research, investigations on the ironing effect during screw extrusion-based material deposition are explored using a set of wider nozzles (w/d as high as 40). Special emphasis is laid on the deposited surface finish, interlayer strength, and geometrical conformance of the extrusion. The nozzle diameter and the stand-off distance (SOD) are also independently varied. It is found that the best dimensional stability is achieved when the SOD is set between 75 % and 100 % of the nozzle diameter. Ironing improved the surface finish and the interlayer strength in all instances, with an average improvement of 50 % and 200 %, respectively.

增材制造（AM）是一种新型制造工艺，可通过分层沉积实现特定三维模型的物理实现。材料挤压（MEX）是各种增材制造技术中应用最广泛的一种，其中基于螺杆挤压的增材制造（SEAM）工艺在材料处理和流速能力方面具有最通用的特性。它包括通过挤出机螺杆连续挤出半固态材料。熨烫是 MEX 技术中的常见做法，目的是在沉积时保持 Z 高度并改善表面形态。大多数用于 MEX 的商用喷嘴都是薄壁喷嘴，因此喷嘴宽度与直径之比（w/d）接近 1。在本研究中，我们使用一组更宽（w/d 高达 40）的喷嘴，探索了螺杆挤压材料沉积过程中的熨烫效应。特别强调了挤压过程中的沉积表面光洁度、层间强度和几何一致性。喷嘴直径和间距（SOD）也是独立变化的。结果发现，当 SOD 设置在喷嘴直径的 75 % 到 100 % 之间时，可获得最佳的尺寸稳定性。在所有情况下，熨烫都能改善表面光洁度和层间强度，平均改善幅度分别为 50 % 和 200 %。

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引用次数: 0

Evaluation and quantification of diffusion wear between cutting chip and workpiece using forging press 使用锻造压力机评估和量化切屑与工件之间的扩散磨损

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.075

Junichi Nakagawa , Yusuke Yoshimi , Katsumasa Chiba , Ryutaro Tanaka

The state of the interface between the workpiece and the cutting tool affects the cutting temperature and pressure on the tool surface during the cutting process. In particular, while cutting difficult-to-cut materials such as Ni-based alloy 718, the workpiece exhibits a high affinity for cutting tool materials and could easily adhere to them. Adhesion can, at times, adversely affect productivity. The diffusion between the cutting tool and the workpiece is a factor considered to contribute to the adhesion phenomenon during cutting. Addressing this issue involves choosing tool materials and coated materials with high resistance to diffusion and optimizing cutting conditions, particularly the cutting speed, which significantly impacts cutting temperature. However, because cutting tool wear comprises various forms, clarifying the effect of diffusion on tool wear remains open. In this study, to reproduce the diffusion phenomenon between cutting tool and workpiece, two pairs of test specimens were prepared: (1) cemented carbide-AISI 1045 and (2) cemented carbide-Alloy718, which could be held at high temperature under vacuum conditions by a forging press. The degree of diffusion phenomena was evaluated at each tool-work material interface, and the quantification of diffusion amount was performed by diffused element in each work material. Additionally, the theoretical analysis of the diffusion phenomenon using the thermodynamic and phase diagram calculation software Thermo-Calc was also performed.

在切割过程中，工件与切割工具之间的界面状态会影响切割温度和工具表面的压力。特别是在切削镍基合金 718 等难切削材料时，工件与切削工具材料的亲和力很高，很容易发生粘附。粘附有时会对生产率产生不利影响。切削工具和工件之间的扩散被认为是造成切削过程中粘附现象的一个因素。要解决这一问题，就必须选择抗扩散能力强的刀具材料和涂层材料，并优化切削条件，特别是对切削温度有重大影响的切削速度。然而，由于切削刀具的磨损形式多种多样，因此澄清扩散对刀具磨损的影响仍是一个未知数。在本研究中，为了再现切削工具和工件之间的扩散现象，制备了两对测试试样：(1) 硬质合金-AISI 1045 和 (2) 硬质合金-Alloy718，这两对试样可通过锻造压力机在真空条件下保持高温。对每种工具-材料界面的扩散现象程度进行了评估，并按每种工作材料中的扩散元素对扩散量进行了量化。此外，还使用热力学和相图计算软件 Thermo-Calc 对扩散现象进行了理论分析。

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引用次数: 0

Effect of laser beam incident angle on welding of Ti6Al4V with fiber lasers 激光束入射角对使用光纤激光器焊接 Ti6Al4V 的影响

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.057

Jigar Krushna Pathak, N. Ramesh Babu, D.S. Srinivasu

Laser beam welding (LBW) is widely used for welding Ti6Al4V alloys in aerospace applications. LBW has localized high-energy fluence with low-energy input compared to other fusion welding processes, resulting in narrower heat-affected zones. On the other hand, most metals are highly reflective when the laser beam impinges perpendicular to the surface, making the process inefficient. Hence, this work proposes to employ shallow angle incidence to reduce the reflectivity during the welding of Ti6Al4V material. To explore the potential of this idea, the current study focuses on studying the effect of laser incident angle (15°-90°), power (300 W-1500 W), and feed rate (10 mm/s-25 mm/s) on autogenous weld bead geometry. For this purpose, bead-on plate (BOP) LBW is conducted on mill-annealed Ti6Al4V material of dimensions 25 mm × 25 mm × 3 mm by employing a fiber laser source with a maximum power of 3 kW and a wavelength of 1080 nm. It is observed from the results that at a normal incident angle and low laser power (< 600 W), the penetration depth is too low to generate a weld bead. Analyzing the cross-section of the weld bead, obtained from SEM, perpendicular to the weld direction reveals that the increase in laser incident angle up to an optimal angle resulted in increased bead dimensions (width and height), and beyond that, the dimensions decreased. However, the optimal incident angle changed when the laser power was changed. The major finding of this study is that at 600 W and a normal incident angle, the laser could not penetrate and generate a weld bead due to low absorptivity, while at an incident angle of 30⁰, 45⁰, and 60⁰, weld beads are generated because of increased absorptivity. Similarly, the increase in weld dimensions with the increase in laser power is observed. At higher laser power, underfill and oxide formation are observed. The feed rate is less predominant than the incident angle and the power.

激光束焊接（LBW）广泛应用于航空航天领域的 Ti6Al4V 合金焊接。与其他熔化焊接工艺相比，激光束焊接具有局部高能通量和低能量输入的特点，因此热影响区更窄。另一方面，当激光束垂直于金属表面时，大多数金属都具有很强的反射性，从而使焊接过程效率低下。因此，这项工作建议在焊接 Ti6Al4V 材料时采用浅角入射来降低反射率。为了探索这一想法的潜力，目前的研究侧重于研究激光入射角（15°-90°）、功率（300 W-1500 W）和进给速度（10 mm/s-25 mm/s）对自生焊珠几何形状的影响。为此，采用最大功率为 3 kW、波长为 1080 nm 的光纤激光源，在尺寸为 25 mm × 25 mm × 3 mm 的轧制退火 Ti6Al4V 材料上进行了焊珠在板上 (BOP) 低温焊接。从结果中可以看出，在正常入射角和低激光功率（< 600 W）条件下，穿透深度太低，无法产生焊珠。通过扫描电子显微镜（SEM）获得的垂直于焊接方向的焊缝横截面分析表明，激光入射角增加到最佳角度时，焊缝尺寸（宽度和高度）增加，超过最佳角度后，焊缝尺寸减小。然而，当激光功率改变时，最佳入射角也随之改变。这项研究的主要发现是，在 600 W 和正常入射角时，由于吸收率低，激光无法穿透并产生焊珠，而在 300、450 和 600 入射角时，由于吸收率增加，焊珠得以产生。同样，随着激光功率的增加，焊缝尺寸也会增加。在较高的激光功率下，会出现填充不足和氧化物形成。与入射角和功率相比，进给速度的影响较小。

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引用次数: 0

Heat partition evaluation during dry drilling of thick CFRP laminates with polycrystalline diamond drills 用多晶金刚石钻头干钻厚 CFRP 层压板时的热分区评估

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.059

Fahim Shariar , Umut Karagüzel , Yiğit Karpat

Since various material properties of carbon fiber-reinforced polymer (CFRP) are temperature dependent, dry drilling of CFRP is a delicate process. Thermal damage can be caused by a rise in temperature during drilling due to a large portion of heat being transferred into the material. Heat partition is used to quantify this, which represents the percentage of total heat being dissipated into the constituent objects during a machining operation. Drill margin and contact conditions at the tool-workpiece interface significantly affect the drilling of CFRP material. Drilling experiments were performed to measure thrust force, torque, and temperatures for five different sets of feed rates and rotational speeds. This study proposes a method for calculating heat partition values during CFRP drilling by developing a finite element-based thermal model. The FE model employs a Gaussian distributed ring-type heat flux that is a function of the equivalent contact length at the interface between the drill and the material surface and the geometry of the workpiece which operates as a moving heat source, emulating the progress of the drill through the CFRP laminate. The tool implements heat fluxes that use characteristic time-point-based step functions to represent the temperature on the drill as it advances through the workpiece during machining. The temperature profiles obtained from the FE analysis and the experiments for the workpiece and tool were subsequently matched iteratively to determine the corresponding heat partition value.

由于碳纤维增强聚合物（CFRP）的各种材料特性与温度有关，因此碳纤维增强聚合物的干式钻孔是一个微妙的过程。在钻孔过程中，由于大量热量传入材料，温度升高会造成热损伤。热分区用于量化这种情况，它表示在加工操作过程中散失到组成物体中的热量占总热量的百分比。钻孔余量和刀具-工件界面的接触条件对 CFRP 材料的钻孔有很大影响。钻孔实验测量了五组不同进给率和转速下的推力、扭矩和温度。本研究通过开发基于有限元的热模型，提出了一种计算 CFRP 钻孔过程中热分区值的方法。该有限元模型采用高斯分布环型热通量，它是钻头与材料表面界面等效接触长度和工件几何形状的函数，可作为移动热源，模拟钻头穿过 CFRP 层压板的过程。该工具使用基于时间点的特征阶跃函数实现热通量，以表示钻头在加工过程中穿过工件时的温度。从 FE 分析和实验中获得的工件和刀具的温度曲线随后进行迭代匹配，以确定相应的热分区值。

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引用次数: 0

3D melt blowing of Elastollan thermoplastic polyurethane for tissue engineering applications: A pilot study 用于组织工程应用的 Elastollan 热塑性聚氨酯三维熔体吹塑：试点研究

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.043

Advay Pawar , Bruce Anderson , Behnam Pourdeyhimi , Amy L. McNulty , Matthew Fisher , Rohan Shirwaiker

Scaffolds, in addition to being biocompatible, should possess structural and mechanical properties similar to the natural tissues they intend to replace. Many tissue engineering applications require porous 3D scaffolds characterized by unique microfibrous organization and mechanical anisotropy. Manufacturing process principles and process parameter-biomaterial interactions ultimately govern the properties that can be achieved in the scaffold. In this study, we investigate a recently developed nonwoven scaffold fabrication process, 3D melt blowing (3DMB), for processing Elastollan®, a thermoplastic polyurethane with basic mechanical properties suitable for musculoskeletal tissue engineering. The range of feasible processing parameters was screened and the effects of two sets of critical process parameters (fiber deposition offset and surface velocity of the collector) that produced contrasting scaffold morphologies were assessed. Results showed that scaffolds of Group B that were fabricated at the higher fiber deposition offset (90 %) and higher surface velocity of the collector (6 × 10⁵ mm/min) possessed significantly smaller fiber diameter and higher porosity and degree of fiber alignment along the principal direction of collector rotation during 3DMB (all p < 0.05) compared to Group A scaffolds (fabricated at 50 % offset and 1 × 10⁵ mm/min surface velocity). Although both groups possessed similar tensile stiffness, the elongation at failure was significantly different (p < 0.0001). The higher elongation at failure of Group B correlated with the higher degree of fiber alignment in these scaffolds. In contrast, the more isotropic fibrous organization of Group A contributed to their higher compressive stiffness (p = 0.004). The introduction of NaOH treatment to improve hydrophilicity of the scaffolds resulted in a significant reduction of tensile stiffness of Group A (p < 0.05) but not Group B. This treatment did not significantly affect the elongation at failure or compressive stiffness of both groups. With NaOH-treatment, both groups demonstrated good biocompatibility when seeded with fibroblast cells over 14 days. This study confirms the ability to fabricate via 3DMB, biocompatible, micro-fibrous, Elastollan scaffolds relevant for musculoskeletal tissue engineering.

支架除了具有生物相容性外，还应该具有与要替代的天然组织相似的结构和机械特性。许多组织工程应用要求多孔三维支架具有独特的微纤维组织和机械各向异性。制造工艺原理以及工艺参数与生物材料之间的相互作用最终决定了支架所能达到的性能。在本研究中，我们研究了最近开发的一种无纺布支架制造工艺--三维熔体吹塑（3DMB），用于加工 Elastollan®，这是一种热塑性聚氨酯，具有适合肌肉骨骼组织工程的基本机械性能。对可行的加工参数范围进行了筛选，并评估了两组关键加工参数（纤维沉积偏移量和收集器表面速度）对产生截然不同的支架形态的影响。结果显示，与 A 组支架（以 50% 的偏移量和 1 × 105 mm/min 的表面速度制造）相比，以较高的纤维沉积偏移量（90%）和较高的收集器表面速度（6 × 105 mm/min）制造的 B 组支架具有明显较小的纤维直径、较高的孔隙率以及在 3DMB 期间沿收集器主要旋转方向的纤维排列程度（所有 p < 0.05）。虽然两组具有相似的拉伸刚度，但破坏时的伸长率却有显著差异（p < 0.0001）。B 组较高的破坏伸长率与这些支架中较高的纤维排列程度有关。相比之下，A 组的纤维组织各向同性更强，因此抗压刚度更高（p = 0.004）。为提高支架的亲水性而引入 NaOH 处理会显著降低 A 组的拉伸刚度（p < 0.05），但不会降低 B 组的拉伸刚度。经 NaOH 处理后，两组在 14 天内播种成纤维细胞时均表现出良好的生物相容性。这项研究证实了通过 3DMB 制造生物相容性微纤维 Elastollan 支架的能力，这种支架适用于肌肉骨骼组织工程。

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