Manufacturing Letters最新文献

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Surface topographical and morphological features of submerged waterjet peened AZ91D Mg alloy surfaces – A preliminary study 浸没水射流喷丸AZ91D镁合金表面形貌及形态特征的初步研究

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-10-13 DOI: 10.1016/j.mfglet.2025.09.004

Mugilvalavan Mohan , Thirumavalavan Krishnamurthy , Muruganandhan Radhakrishnan , Arunkumar Thirugnanasambandam

This research examines surface modifications in AZ91D magnesium alloy through submerged waterjet peening with varying parameters. A significant outcome is the achievement of a S_ku > 3, indicating a valley-dominated surface profile highly favourable for micro-lubricant retention and improved corrosion and tribological performance. Maximum surface variations were observed at D_c = 0.75 mm, v = 90 mm/min, and NOP = 5, resulting in a S_ku value of 10.107 ± 0.32 and also S_sk value indicating a valley-dominated profile. The enhanced S_ku value is attributed to intensified cavitation effects from the cumulative bubble collapse under high-pressure waterjet. Moreover, a maximum microhardness of 155 ± 13.9HV_0.1 was obtained at D_c = 1 mm, v = 90 mm/min, and NOP = 1, highlighting an optimal balance between plastic deformation and surface integrity. Surface morphology of selected peened samples indicates that prolonged exposure to high-pressure waterjet under submerged conditions led to intensified erosion, characterised by deeper valleys, micro-depressions, and craters, correlating with energy dispersion and material erosion, which indicates that SWP effectively modifies surfaces using only water and mechanical energy, avoiding chemical treatments and hazardous by-products. This makes SWP a sustainable surface modification technique and a promising green alternative for improving material performance across various industrial applications. However, further investigations are needed to optimise parameters and fully understand surface characteristics.

研究了不同参数下浸没水射流强化AZ91D镁合金的表面改性。一个重要的成果是实现了Sku >； 3，表明山谷主导的表面轮廓非常有利于微润滑剂的保留，并改善了腐蚀和摩擦学性能。在Dc = 0.75 mm, v = 90 mm/min和NOP = 5时，表面变化最大，Sku值为10.107±0.32，Ssk值也显示山谷主导剖面。高压水射流作用下，累积气泡破裂引起的空化作用加剧了Sku值的增大。此外，在Dc = 1 mm, v = 90 mm/min, NOP = 1时，获得的最大显微硬度为155±13.9HV0.1，突出了塑性变形和表面完整性之间的最佳平衡。所选喷淋样品的表面形貌表明，在淹没条件下长期暴露于高压水射流导致侵蚀加剧，其特征是更深的山谷、微洼地和陨石坑，与能量分散和物质侵蚀相关，这表明SWP仅利用水和机械能有效地改变表面，避免了化学处理和有害的副产品。这使得SWP成为一种可持续的表面改性技术，也是一种有前途的绿色替代方案，可以改善各种工业应用中的材料性能。然而，需要进一步的研究来优化参数并充分了解表面特征。

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引用次数: 0

Application of phone-based robotic arm teleoperation in remote hands-on labs for engineering education 基于电话的机械臂遥操作在工程教育远程动手实验室中的应用

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-10-13 DOI: 10.1016/j.mfglet.2025.10.005

Ziling Chen, Zhen Zhao, John Liu

Remote manufacturing education often struggles to deliver authentic hands-on experiences. We developed TeleopLab, an intuitive teleoperation system that enables students to control a robotic arm and laboratory equipment remotely through a smartphone motion interface and commonly available meeting software. Designed for accessibility and minimal setup, TeleopLab preserves the interactivity and complexity of physical laboratories in an online environment. When deployed in an advanced manufacturing course, it supported iterative 3D printing optimization tasks in real time. The educational impact of TeleopLab was evaluated using the Motivated Strategies for Learning Questionnaire (MSLQ), with pre- and post-use data collected from six students. The results showed improvements in self-efficacy and motivation to re-engage, along with a reduction in fear of making mistakes among students during the lab activities. TeleopLab highlights the potential of a scalable, cost-effective solution for remote hands-on learning.

远程制造教育往往难以提供真实的实践经验。我们开发了TeleopLab，这是一个直观的远程操作系统，使学生能够通过智能手机运动界面和常用的会议软件远程控制机械臂和实验室设备。TeleopLab专为可访问性和最小设置而设计，在在线环境中保留了物理实验室的交互性和复杂性。当部署在先进制造课程时，它支持实时迭代的3D打印优化任务。使用动机学习策略问卷（MSLQ）评估TeleopLab的教育影响，并收集了6名学生使用前后的数据。结果显示，学生在自我效能和重新参与的动机方面有所提高，同时在实验室活动中对犯错的恐惧也有所减少。TeleopLab强调了远程动手学习的可扩展、经济高效的解决方案的潜力。

引用次数: 0

A LEGO®-themed introduction to manufacturing course developed for first-year undergraduate students 乐高®为一年级本科生开发的以制造为主题的入门课程

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-10-13 DOI: 10.1016/j.mfglet.2025.10.010

John Liu, Daniel Braconnier, Zhen Zhao, Kaitlyn Gee, Kaitlyn P. Becker, A. John Hart

Undergraduate engineering curricula have commonly struggled to capture students’ imagination and interest for manufacturing. Most undergraduate engineering programs give students limited and late opportunities to learn manufacturing. To stimulate students’ interest in manufacturing earlier, we present the development and implementation of a LEGO®-themed freshman manufacturing course. The course is composed of interactive lectures, hands-on labs, factory visits, and team project-based learning. Survey findings from the spring 2024 course yield gains in attitudes, understanding, and skills in manufacturing. While manufacturing programs are traditionally predominantly male, the class’s enrollment was 75 % women, demonstrating the course’s promise to engage a diverse audience.

本科工程课程通常难以激发学生对制造业的想象力和兴趣。大多数本科工程课程给学生有限的学习制造的机会。为了更早地激发学生对制造的兴趣，我们提出了一个乐高®主题的新生制造课程的开发和实施。课程由互动讲座、动手实验、工厂参观和团队项目学习组成。2024年春季课程的调查结果显示，制造业的态度、理解和技能都有所提高。虽然制造业课程传统上以男性为主，但该课程的女性入学率为75%，这表明该课程有望吸引不同的受众。

引用次数: 0

Development of digital laboratory modules using computer simulation for enhanced learning experience in manufacturing education 利用计算机模拟开发数字实验室模块，以增强制造业教育的学习体验

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-10-12 DOI: 10.1016/j.mfglet.2025.10.009

S.M. Atikur Rahman , Selim Molla , Jakia Sultana , Richard Y. Chiou , Tzu-Liang (Bill) Tseng , Md. Fashiar Rahman

The complexity of modern manufacturing environments, characterized by interactions among various entities, variability, and randomness, presents significant challenges for learners. Understanding these dynamics is essential, but traditional classroom-only focused education often falls short in providing students with practical insights. Hands-on experimentation is vital for students to observe interactions and experience process manipulations, yet such experimental setups can be costly and impractical for many institutions. This paper presents the development of digital laboratory modules to enhance students’ learning experience in manufacturing education through computer simulation techniques. Two modules were created to address complex manufacturing issues: production design under demand uncertainty, manufacturing layout design, and different maintenance schedules. These modules allow users to control process parameters, design experiments, run simulations, and observe outcomes, promoting informed decision-making without wasting resources. This approach is particularly valuable for resource-constrained industries, facilitating rapid decision-making and process efficiency. Each module uses case studies with background information, problem statements, datasets, and expected results. The paper details the development process and case studies and includes experimentation guidelines for using the modules effectively in educational settings.

现代制造环境的复杂性，以各种实体之间的相互作用、可变性和随机性为特征，对学习者提出了重大挑战。了解这些动态是必不可少的，但传统的课堂教育往往不能为学生提供实用的见解。动手实验对于学生观察互动和体验过程操作是至关重要的，然而这种实验设置对许多机构来说可能是昂贵和不切实际的。本文介绍了利用计算机仿真技术开发数字化实验模块，以提高学生在制造教育中的学习体验。创建了两个模块来解决复杂的制造问题：需求不确定性下的生产设计、制造布局设计和不同的维护计划。这些模块允许用户控制过程参数，设计实验，运行模拟，并观察结果，促进明智的决策而不浪费资源。这种方法对于资源受限的行业特别有价值，可以促进快速决策和流程效率。每个模块都使用带有背景信息、问题陈述、数据集和预期结果的案例研究。本文详细介绍了开发过程和案例研究，并包括在教育环境中有效使用这些模块的实验指南。

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引用次数: 0

Hybrid education and training approaches enabling workforce development in additive manufacturing 混合教育和培训方法使增材制造的劳动力发展成为可能

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-10-12 DOI: 10.1016/j.mfglet.2025.10.007

Abhishek Singh, Pinyi Wu, Bhavana Komaraju, Chinedum E. Okwudire, Mihaela Banu

Additive Manufacturing (AM) has gained wide attention in the past two decades and emerged as a significant method in the manufacturing sector. Advancements in AM have enhanced productivity, reduced lead times, and improved part quality while maintaining cost-effectiveness. Despite advancements in materials, technologies, and parameter optimization, the widespread AM adoption is limited by a lack of skilled workforce. This research presents a hybrid learning approach to address this gap through curricula and hands-on training. The proposed framework includes hybrid educational and training approaches in polymer-based FFF, SLA, SLS, and Metal FFF technologies toward the development of a workforce skilled in AM.

在过去的二十年里，增材制造（AM）得到了广泛的关注，并成为制造业的一种重要方法。增材制造的进步提高了生产率，缩短了交货时间，提高了零件质量，同时保持了成本效益。尽管在材料、技术和参数优化方面取得了进步，但由于缺乏熟练的劳动力，AM的广泛采用受到限制。本研究提出了一种混合学习方法，通过课程和实践培训来解决这一差距。提议的框架包括基于聚合物的FFF、SLA、SLS和金属FFF技术的混合教育和培训方法，以培养AM技术熟练的劳动力。

引用次数: 0

Advancing manufacturing engineering education through sustainability integration 通过可持续性整合推进制造工程教育

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-10-12 DOI: 10.1016/j.mfglet.2025.10.008

Dalya Ismael, Vukica Jovanovic

As global industries adopt advanced technologies and face rising environmental pressures, manufacturers increasingly seek engineers able to drive sustainable innovation. Yet sustainability remains under-integrated in many engineering courses, particularly in manufacturing programs. This study addresses that gap by embedding the Engineering for One Planet (EOP) framework into three courses: a Lean Engineering course and two capstone design courses. Six EOP topics were embedded through experiential learning. Retrospective surveys and photovoice reflections showed gains in life-cycle thinking, environmental analysis, and sustainable business models, enhancing motivation, contextual understanding, and workforce readiness

随着全球工业采用先进技术并面临日益增长的环境压力，制造商越来越多地寻求能够推动可持续创新的工程师。然而，在许多工程课程中，特别是在制造课程中，可持续性仍然没有得到充分的整合。本研究通过将“地球工程”（EOP）框架嵌入三门课程来解决这一差距：一门精益工程课程和两门顶点设计课程。通过体验式学习嵌入6个EOP主题。回顾性调查和语音照片反映显示，在生命周期思维、环境分析和可持续商业模式、增强动机、背景理解和劳动力准备方面取得了进展

引用次数: 0

Adapting instructional strategies to enable HyFlex learning for manufacturing internship students 调整教学策略，为制造业实习学生提供HyFlex学习

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-10-12 DOI: 10.1016/j.mfglet.2025.10.006

Julia L. Morse, Eduard Plett

To address the growing demand for manufacturing and automation engineering professionals, local industry is partnering with Kansas State University Salina Aerospace and Technology Campus to support students through work-study internships, concurrent with students’ academic coursework.

To reduce scheduling conflicts between classroom and workplace commitments, non-lab classes are offered in HyFlex format, allowing students to choose between in-person and asynchronous online participation. Existing teaching strategies and resources were adapted to support HyFlex delivery in six manufacturing and automation courses taught by two instructors. Student performance data and instructor feedback indicate that HyFlex delivery effectively meets learning needs without compromising educational quality.

为了满足对制造和自动化工程专业人才不断增长的需求，当地工业界正在与堪萨斯州立大学萨利纳航空航天和技术校区合作，通过勤工助学实习和学生的学术课程来支持学生。为了减少课堂和工作场所之间的时间安排冲突，非实验室课程以HyFlex格式提供，允许学生在面对面和异步在线参与之间进行选择。现有的教学策略和资源进行了调整，以支持HyFlex在由两名教师教授的六门制造和自动化课程中的交付。学生表现数据和教师反馈表明，HyFlex交付在不影响教育质量的情况下有效地满足了学习需求。

引用次数: 0

Integrating feminist pedagogy into manufacturing education: a digital twin-based teaching module 将女性主义教学法融入制造业教育：基于数字双胞胎的教学模块

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-10-11 DOI: 10.1016/j.mfglet.2025.10.002

Anis Fatima, John L. Irwin

Integrating feminist pedagogy into engineering education offers a novel pathway to make technical learning more inclusive, participatory, and socially responsive. This paper presents the design and classroom implementation of a digital twin-based teaching module that combines sustainable manufacturing concepts with student-centered learning. A CNC milling machine was retrofitted and linked to its virtual counterpart using CAD/CAM tools, open-source controllers, and a custom-developed graphical user interface (GUI). The system captures real-time data on energy consumption and tool vibration, enabling students to explore how machining parameters impact sustainability factors such as power usage and vibration − induced tool wear. Grounded in feminist pedagogical principles, emphasizing collaboration, reflexivity, and co-creation of knowledge, the module was deployed in Smart Manufacturing and Internet of Things (IoT) courses. The approach fostered a more inclusive learning environment by encouraging active participation, shared authority, and critical thinking around engineering practices. Student surveys and course evaluations indicated improved engagement, deeper conceptual understanding, and greater satisfaction. These results highlight the potential of integrating feminist pedagogy with digital twin technology to enhance manufacturing education and better prepare students for the demands of Industry 4.0 and sustainable engineering.

将女性主义教学法整合到工程教育中，提供了一条使技术学习更具包容性、参与性和社会响应性的新途径。本文介绍了一个基于数字孪生的教学模块的设计和课堂实施，该模块将可持续制造概念与以学生为中心的学习相结合。利用CAD/CAM工具、开源控制器和定制开发的图形用户界面（GUI），对数控铣床进行了改造，并将其与虚拟铣床连接起来。该系统捕获能源消耗和刀具振动的实时数据，使学生能够探索加工参数如何影响可持续性因素，如电力使用和振动引起的刀具磨损。该模块以女权主义教学原则为基础，强调协作、反思性和知识的共同创造，被部署在智能制造和物联网（IoT）课程中。该方法通过鼓励积极参与、共享权威和围绕工程实践的批判性思考，培养了一个更具包容性的学习环境。学生调查和课程评估表明，学生的参与度提高了，对概念的理解加深了，满意度也提高了。这些结果突出了将女权主义教学法与数字孪生技术相结合的潜力，以增强制造业教育，并更好地为学生准备工业4.0和可持续工程的需求。

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引用次数: 0

Designing a digital engineering curriculum for manufacturing education: industry-aligned course development 为制造业教育设计数字工程课程：与行业相结合的课程开发

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-10-11 DOI: 10.1016/j.mfglet.2025.10.001

Ana Wooley

Digital Engineering (DE) is transforming the manufacturing landscape by integrating digital tools and processes across the product lifecycle. This paper describes the development and pilot of a DE course in the Industrial and Systems Engineering and Engineering Management (ISEEM) department at the University of Alabama in Huntsville (UAH), offered over two semesters. The course combined student-led literature reviews with presentations from 19 guest speakers across industry, government, and academia. Feedback from students and insights from practitioners helped shape a modular structure for a future DE required course in the ISEEM curriculum.

数字化工程（DE）通过在整个产品生命周期中集成数字化工具和流程，正在改变制造业的格局。本文描述了亨茨维尔阿拉巴马大学工业与系统工程与工程管理（isem）系的DE课程的开发和试点，该课程为期两个学期。这门课程结合了学生主导的文献综述和来自行业、政府和学术界的19位嘉宾的演讲。来自学生的反馈和来自从业者的见解帮助塑造了isem课程中未来DE必修课的模块化结构。

引用次数: 0

Combination of numerical and physical simulations as a new approach to the evaluation of the K-TIG welding process of thick duplex steel plates 将数值模拟与物理模拟相结合作为评价厚双相钢板K-TIG焊接工艺的新方法

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-10-11 DOI: 10.1016/j.mfglet.2025.09.005

Przemysław Zmitrowicz , Maria Emanuela Palmieri , Luigi Tricarico , Jolanta Baranowska

Duplex stainless steels, known for their resistance to corrosion combined with high yield strength, are increasingly used in offshore structures to reduce weight and material usage. The K-TIG welding process offers a solution to meet growing demands for the high-quality, cost-effective welding of duplex steel. It is a process in which, in contrast to the conventional TIG method, the application of high current intensity results in the formation of the so-called “keyhole” effect, enabling deep penetration even in materials of significant thickness. However, the limited flexibility of K-TIG method for modifying welding parameters for thick plates presents challenges. Moreover, different thermal cycles may occur across the weld thickness. This paper proposes an integrated approach combining numerical and physical simulation to optimize the K-TIG welding method for 10 mm duplex steel plates. A three-dimensional thermal model was developed using COMSOL Multiphysics, simulating the heat transfer and thermal cycles across the heat-affected zone, which was used in physical simulations conducted using a Gleeble 3180 system. The results show that thermal cycles vary significantly across the weld thickness, leading to microstructural differences that could influence the mechanical and corrosion properties of the welded joint. The proposed methodology provides an effective tool for optimizing the K-TIG process, offering insights into thermal cycles, microstructure evolution, and overall weld quality in thick duplex steel plates.

双相不锈钢以其耐腐蚀和高屈服强度而闻名，越来越多地用于海上结构，以减轻重量和材料使用量。K-TIG焊接工艺提供了一种解决方案，以满足日益增长的高质量，高成本效益的双相钢焊接需求。在这个过程中，与传统的TIG方法相比，高电流强度的应用导致所谓的“钥匙孔”效应的形成，即使在厚度很大的材料中也能实现深穿透。然而，由于K-TIG法修正厚板焊接参数的灵活性有限，对其提出了挑战。此外，不同的热循环可能发生在不同的焊缝厚度。本文提出了一种数值模拟与物理模拟相结合的方法来优化10mm双相钢板的K-TIG焊接方法。利用COMSOL Multiphysics建立三维热模型，模拟热影响区的传热和热循环，并利用Gleeble 3180系统进行物理模拟。结果表明，热循环随着焊缝厚度的变化而变化，导致微观组织的差异，从而影响焊接接头的力学性能和腐蚀性能。所提出的方法为优化K-TIG工艺提供了有效的工具，提供了对厚双相钢板热循环、微观结构演变和整体焊接质量的见解。

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