Manufacturing Letters最新文献_第9页

Multi-layer multi-variable value stream mapping: A comprehensive framework across operational, environmental, and social layers with integrated KPIs interrelationships 多层多变量价值流映射：跨操作层、环境层和社会层的综合框架，具有集成的kpi相互关系

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.023

Ayoub Heydarzade , Niloofar Rezaei , Seyed Alireza Vaezi , Jaime A. Camelio

Industry 4.0 technologies have increased the complexity and interconnectivity of manufacturing systems, challenging the conventional scope of Value Stream Mapping (VSM). In response, this paper proposes a Multi-Layer Multi-Variable Value Stream Mapping (MLMV-VSM) framework that integrates operational, environmental, and social layers within a single methodology. The approach captures Key Performance Indicators (KPIs) and their interdependencies, enabling more balanced system optimization. Unlike traditional VSM, MLMV-VSM explicitly incorporates human-centric metrics, such as stress and fatigue, along with operational and environmental factors. An illustrative example demonstrates how operator skill development can influence production speed, energy consumption, and ergonomic outcomes, highlighting cross-layer trade-offs and synergies. The paper also addresses practical challenges, including the measurement of social metrics, the prioritization of competing KPIs, and the need for real-time adaptability. Finally, avenues for future work are identified, emphasizing the integration of Industry 4.0 technologies such as the Internet of Things (IoT) and data analytics to support dynamic decision-making and foster sustainable manufacturing practices.

工业4.0技术增加了制造系统的复杂性和互联性，挑战了价值流映射（VSM）的传统范围。作为回应，本文提出了一个多层多变量价值流映射（MLMV-VSM）框架，该框架将运营层、环境层和社会层集成在一个单一的方法中。该方法捕获关键性能指标（kpi）及其相互依赖性，从而实现更平衡的系统优化。与传统的VSM不同，MLMV-VSM明确地结合了以人为中心的指标，如压力和疲劳，以及操作和环境因素。一个说明性的例子说明了操作员技能的发展如何影响生产速度、能源消耗和人体工程学结果，突出了跨层的权衡和协同作用。本文还讨论了实际的挑战，包括社会指标的度量、竞争kpi的优先级以及对实时适应性的需求。最后，确定了未来工作的途径，强调工业4.0技术（如物联网（IoT）和数据分析）的集成，以支持动态决策和促进可持续制造实践。

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引用次数: 0

Computed Tomography Image-Based Measurements of Cortical Bone Thickness for Improved Bone Tissue Processing and Decision-Making 基于计算机断层成像的皮质骨厚度测量改善骨组织处理和决策

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.019

Dane Ungurait , Chuanshen Zhou , Kateland Hutt , Yunxia Chen , Adam Poniatowski , Joe Shaara , Paxton Howell , Yong Huang , Hitomi Yamaguchi

Due to challenges with sourcing tissues for autografts, allografts are becoming increasingly popular in the transplantation of human tissue, including bone grafting, and it is important that available donor tissue is processed efficiently while minimizing discarded tissue. This paper describes the development of a computed tomography (CT) image-based system to nondestructively measure cortical-bone thickness of a donor sample, which helps determine how the tissue should be processed to maximize tissue utilization. The system uses a CT scanner to collect three-dimensional data of the donor tissue. The data is then processed into two-dimensional tomograms, which are processed using software developed to measure cortical-bone thickness. Based on these measurements, a score is assigned to the cortical bone that helps determine the types and sizes of allografts that can be processed from the tissue. It was demonstrated that high-resolution (85–200 microns) images can be generated and analyzed quickly with scan times as fast as 8 min and software run times of less than 5 seconds for 464 thickness measurements. This paper concludes that this process is an effective and efficient method to generate quantitative metrics that can be used to make more informed decisions on the processing of bone tissue for allograft production.

由于自体移植物组织来源的挑战，同种异体移植物在人体组织移植（包括骨移植）中越来越受欢迎，重要的是有效地处理可用的供体组织，同时尽量减少丢弃的组织。本文描述了一种基于计算机断层扫描（CT）图像的系统的发展，该系统用于无损测量供体样本的皮质骨厚度，这有助于确定如何处理组织以最大限度地利用组织。该系统使用CT扫描仪收集供体组织的三维数据。然后，这些数据被处理成二维断层图，然后使用用于测量皮质骨厚度的软件进行处理。基于这些测量，对皮质骨进行评分，以帮助确定可以从组织中处理的同种异体移植物的类型和大小。结果表明，高分辨率（85-200微米）图像可以快速生成和分析，扫描时间快至8分钟，软件运行时间不到5秒，可测量464个厚度。本文的结论是，该过程是一种有效和高效的方法，可以产生定量指标，可用于制定更明智的决策，处理同种异体移植物生产的骨组织。

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引用次数: 0

Modeling of adhered powder particles and waviness on additive manufacturing part surface in electrochemical polishing 电化学抛光过程中增材制造零件表面附着粉末颗粒和波纹度的建模

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.040

Wenjian Cao , Andrea Ghiotti , Stefania Bruschi

An innovative approach in electrochemical polishing (ECP) has been developed to enhance surface quality and precision in post-processing additive manufacturing surfaces, with a particular focus on leveling adhered powders and mitigating surface waviness. This study introduces a novel 2D model for quantitatively simulating the material removal process of spherical powder residues and waviness on sintered surfaces, utilizing adaptive triangular meshing technology. The initial geometric profiles of surface defects were modeled using the ellipse equation for spherical powder particles and the sine function for surface waviness. Key profile control nodes were tracked to observe changes over time, with detailed analyses of electric field strength, current density, material removal thickness, and removal rate. Predictive modeling results indicate that the electric field direction remains parallel to the surface, and the current density is approximately 0.23A cm⁻² after ECP, achieving a consistent material removal rate of 0.28 μm min⁻¹ during polishing. Surface roughness measurements, taken over a sampling length of 500 µm, showed a reduction from Ra 3.74 μm to Ra 0.21 μm, and the comparison of simulated and experimental surface profiles was presented with an error of only 0.04 μm, demonstrating the method’s efficacy in finishing both adhered powders and waviness. This study provides a new perspective to investigate the mechanism of ECP additive manufacturing parts.

电化学抛光（ECP）的一种创新方法已经被开发出来，以提高后处理增材制造表面的表面质量和精度，特别关注于平整粘附粉末和减轻表面波纹。本文采用自适应三角网格技术，建立了一种新的二维模型，用于定量模拟烧结表面球形粉末残留和波纹的材料去除过程。采用椭圆方程模拟球形粉末颗粒表面缺陷的初始几何轮廓，用正弦函数模拟表面波纹度。跟踪关键剖面控制节点，观察随时间的变化，并详细分析电场强度、电流密度、材料去除厚度和去除率。预测模型结果表明，电场方向与表面保持平行，ECP后电流密度约为0.23A cm−2，抛光过程中材料去除率保持在0.28 μ min−1。采样长度为500µm时，表面粗糙度测量结果显示Ra从3.74 μm降低到0.21 μm，模拟和实验表面轮廓的比较误差仅为0.04 μm，表明该方法在处理粘附粉末和波纹方面都是有效的。本研究为研究ECP增材制造零件的机理提供了新的视角。

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引用次数: 0

Using machine learning with supplemented NC code to predict machining energy 利用机器学习辅助数控代码预测加工能量

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.086

Samuel Stencel , Nathan Hartman

Manufacturing contributes a significant amount of value to the economy while consuming nearly one-third of the total energy produced within the nation. Computer-aided manufacturing tools arose to streamline the process of manufacturing parts, but they lack energy-conscious practices. With this gap, research has been done in the development of mechanistic and data-driven models to accurately predict the energy consumption of this process. However, validation carried out in the experimental methodology in many of the research models is ill-fit to represent their realistic counterparts. In this paper, a data-driven deep learning model is developed, which properly accounts for the complexities associated with CNC machining, as it compensates for variations in operations observed during CNC machining. Furthermore, this deep learning model makes predictions by processing supplemented NC programs sequentially. These programs include additional information regarding the material removal process. Four variants of the model are created to provide insights into the effects of supplementing the program with different material removal variables. The variables include depth of cut, width of cut, material removal rate, and the volume of material removed per numerically controlled instruction. The prediction capability of these four models are then compared using several statistical tests.

制造业为经济贡献了大量价值，同时消耗了全国近三分之一的能源。计算机辅助制造工具的出现是为了简化零件制造过程，但它们缺乏节能意识。有了这一差距，研究人员已经在开发机械和数据驱动的模型来准确预测这一过程的能耗。然而，在许多研究模型中，以实验方法进行的验证不适合代表其现实对应物。在本文中，开发了一个数据驱动的深度学习模型，该模型适当地解释了与CNC加工相关的复杂性，因为它补偿了CNC加工过程中观察到的操作变化。此外，该深度学习模型通过顺序处理补充的NC程序来进行预测。这些程序包括关于材料去除过程的附加信息。该模型的四个变体被创建，以提供对使用不同材料去除变量补充程序的效果的见解。变量包括切割深度，切割宽度，材料去除率，以及每个数控指令去除的材料体积。然后用几种统计检验比较了这四种模型的预测能力。

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引用次数: 0

Balancing trade-offs between first three moments of completion times for one-stage production 在一期生产的前三个完井时刻之间进行平衡

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.011

Wei Li , Barrie R. Nault

For one-stage production, operations management faces the following three challenges to make decisions, which are inconsistencies between key performance indicators (KPIs) for production, trade-offs between the expected return and the risk in modern portfolio theory (MPT), and uncertainties in processing times. Traditionally, total completion time (TCT) and variance of completion times (VCT) are two KPIs for one-stage production scheduling, which relate to the first and second moments of completion times, respectively. We question whether the third moment of completion times is good to address the three challenges. In this paper, we introduce the skewness of completion times (SCT) in scheduling, and propose the ToB(

a, b

) heuristics for trade-off balancing. Through case studies with 5 levels of processing time uncertainties and compared to existing ToB(

α

) heuristics which balance trade-offs between TCT and VCT, we show that our ToB(

a, b

) heuristics dominate ToB(

α

) heuristics in terms of smaller expected values (E) of weighted sum of deviations from the best solutions of KPIs and smaller risks (

σ

) associated with these KPI deviations. Therefore, our ToB(

a, b

) heuristics are more robust to balance trade-offs between the three KPIs under processing time uncertainties.

对于单阶段生产，运营管理在决策时面临以下三个挑战，即生产关键绩效指标（kpi）之间的不一致性，现代投资组合理论（MPT）中预期回报与风险之间的权衡，以及加工时间的不确定性。传统上，总完工时间（TCT）和完工时间方差（VCT）是单阶段生产调度的两个kpi，它们分别与完成时间的第一时刻和第二时刻有关。我们质疑完成时间的第三个时刻是否适合解决这三个挑战。本文引入了调度中完成时间的偏度问题，并提出了ToB（a,b）启发式的权衡平衡算法。通过5级处理时间不确定性的案例研究，并与现有的ToB（α）启发式方法进行比较，该启发式方法平衡了TCT和VCT之间的权衡，结果表明，我们的ToB（a,b）启发式方法在KPI最佳解决方案的加权偏差和的期望值(E)较小以及与这些KPI偏差相关的风险（σ）较小方面优于ToB（α）启发式方法。因此，我们的ToB（a,b）启发式方法对于在处理时间不确定性下平衡三个kpi之间的权衡更为稳健。

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引用次数: 0

Tunes of trust: A framework for auditory nudges in human-ai manufacturing collaboration 信任的旋律：人类与人工智能制造合作中的听觉推动框架

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.024

Fatemeh Mozaffar, Logan Smith, Beshoy Morkos

This study investigates the application of musical and voice-based auditory nudges in enhancing human-AI interactions within a manufacturing setting, utilizing nudge theory to improve worker productivity, trust, and engagement. As AI technologies become more widespread in manufacturing environments, effective methods for fostering trust and collaboration between human operators and AI are essential. The increasing demand for customized products and rapid technological advancements in Industry 4.0 (I4.0) necessitate rapid employee adaptation, with humans playing a key role as the Human Component (HC) for its success. Therefore, the relationship between artificial intelligence (AI) and humans as inseparable parts of I4.0 need to be studied. Research has been done on improving the interaction between and performance of AI and humans. The impact of different nudge methods on worker productivity has also been studied, but not as an effective communication tool in human and AI teams. This study proposes a research framework that aims to explore using music as a medium for non-verbal cues, which has been shown to influence emotional perception and enhance task performance such as task continuity and worker productivity. This study employs a mixed-methods approach, incorporating quantitative metrics such as task completion times, alongside qualitative feedback to assess the impact of varied auditory nudges—including musical elements like tempo and pitch—on worker behavior and emotional response. Results from this experimental study will help to demonstrate the viability of musical nudges in increasing trust and efficiency in human-AI collaboration, providing insights into innovative strategies for optimizing Industry 4.0 environments.

本研究探讨了在制造环境中，基于音乐和语音的听觉推动在增强人类与人工智能交互中的应用，利用推动理论来提高工人的生产力、信任和参与度。随着人工智能技术在制造环境中变得越来越普遍，促进人类操作员与人工智能之间信任和协作的有效方法至关重要。在工业4.0 （I4.0）时代，对定制产品的需求不断增长，技术的快速进步要求员工快速适应，而人类作为人类组件（HC）在其成功中发挥着关键作用。因此，人工智能（AI）与作为工业4.0不可分割部分的人类之间的关系需要研究。关于提高人工智能与人类之间的互动和表现的研究已经完成。不同的推动方法对工人生产力的影响也得到了研究，但并没有作为人类和人工智能团队的有效沟通工具。本研究提出了一个研究框架，旨在探索使用音乐作为非语言线索的媒介，这已被证明可以影响情绪感知并提高任务表现，如任务连续性和工作效率。这项研究采用了一种混合方法，结合了任务完成时间等定量指标，以及定性反馈来评估各种听觉刺激（包括节奏和音高等音乐元素）对员工行为和情绪反应的影响。这项实验研究的结果将有助于证明音乐推动在提高人类与人工智能协作的信任和效率方面的可行性，为优化工业4.0环境的创新策略提供见解。

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引用次数: 0

Ultrafast laser micromachining of through-drill trenches in silicon wafers 硅晶圆中通钻沟槽的超快激光微加工

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.087

Chenyang Zhu , Rui Huang , Nian X. Sun , Xin Zhao

Silicon wafer processing is crucial in the semiconductor industry, especially in applications requiring precision through-trench fabrication. This study investigates the impact of various laser fluence, scan counts, and focal point dynamics on the trench width for both the entrance (top) and exit (bottom) surfaces using ultrafast laser machining on silicon wafers. Experiments revealed that while the trench width at the entrance remains nearly constant, the width at the exit increases with higher laser fluence and scan counts, stabilizing once a complete through-drill state is reached. Additionally, dynamic focal point strategy (step processing) experiments at laser fluences of 20 and 30 J/cm², and total scan counts of 300 and 600 were conducted. It was found that when the scan count was below the through-drill threshold, increasing the number of steps led to a wider trench bottom. However, when the scan count exceeded the threshold, the trench width at the bottom reached its maximum at two steps and then decreased with additional steps. Furthermore, the effect of polarization direction on machining quality was assessed, showing improved trench uniformity when the polarization was perpendicular to the trench direction. These findings suggest that a 2-step processing approach, with each step meeting the through-drill scan threshold and maintaining perpendicular polarization to the trench, optimizes micro-machining quality and minimizes taper.

硅晶圆加工在半导体工业中是至关重要的，特别是在需要精密通槽制造的应用中。本研究利用超快激光加工硅片，研究了不同激光能量、扫描次数和焦点动力学对入口（顶部）和出口（底部）表面沟槽宽度的影响。实验表明，虽然入口的沟槽宽度几乎保持不变，但出口的宽度随着激光通量和扫描次数的增加而增加，并在达到完全通钻状态时趋于稳定。此外，在20和30 J/cm2的激光影响下，进行了300和600次总扫描次数下的动态焦点策略（步进处理）实验。研究发现，当扫描次数低于穿透阈值时，增加扫描步数会导致沟槽底部变宽。但是，当扫描次数超过阈值时，底部沟槽宽度在两个步长处达到最大值，然后随着增加步长而减小。此外，还评估了极化方向对加工质量的影响，当极化方向垂直于沟槽方向时，沟槽均匀性得到改善。这些发现表明，两步加工方法，每一步满足通钻扫描阈值并保持垂直于沟槽的极化，可以优化微加工质量并最小化锥度。

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引用次数: 0

New Investigations on the performance Enhancement of Cryogenic-LN2 assisted sustainable milling of titanium alloy 提高低温- ln2辅助钛合金可持续铣削性能的新研究

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.047

Aqib Mashood Khan, Salman Pervaiz, Muhammad Jamil, Wei Zhao, Longhui Meng

The low-temperature properties of the titanium alloy Ti17 affect the milling process. In order to better understand the various physical phenomena in the cryogenic cutting process, cryogenic impact tests and tensile tests of titanium alloy Ti17 were undertaken in this study. Based on the cryogenic performance of the material, experiments on dry milling and cryogenic milling with a liquid nitrogen jet were conducted. It was found that the strength was increased, and the toughness was decreased under cryogenic conditions. The milling force shows an increasing trend with the increase of cutting speed and feed rate under both cooling conditions. The milling forces of cryogenic conditions were higher than that of dry cutting, and the surface roughness under cryogenic conditions was also improved compared to dry cutting. This study highlights how cryogenic milling of Titanium Alloy Ti17 can improve surface roughness and mechanical strength, leading to extended tool life and reduced material waste, which contributes to sustainable manufacturing. Additionally, using cryogenic cooling minimizes the need for conventional cutting fluids, reducing environmental impact and enhancing process sustainability.

钛合金Ti17的低温性能影响铣削过程。为了更好地了解低温切削过程中的各种物理现象，本研究对钛合金Ti17进行了低温冲击试验和拉伸试验。根据材料的深冷性能，进行了干式铣削和液氮射流深冷铣削实验。结果表明，在低温条件下，材料的强度有所提高，韧性有所降低。在两种冷却条件下，铣削力均随切削速度和进给速率的增大而增大。低温条件下的铣削力高于干切削，表面粗糙度也比干切削有所改善。该研究强调了钛合金Ti17的低温铣削如何提高表面粗糙度和机械强度，从而延长刀具寿命并减少材料浪费，从而有助于可持续制造。此外，使用低温冷却最大限度地减少了对传统切削液的需求，减少了对环境的影响，提高了工艺的可持续性。

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引用次数: 0

Carbo-thermal reduction of lunar highland regolith simulant for in-situ manufacturing of SiC 月球高原表层模拟物原位制备碳化硅的碳热还原

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.049

Nithya Srimurugan , Sathyan Subbiah

In-situ resource utilization is important to ensure sustainability of exploration missions such as establishing a habitable extra-terrestrial base on the moon. Resources available on the lunar surface such as the regolith must be tapped to build structures and manufacture products on moon. This requires raw materials like metals, metal alloys and ceramics to be extracted from the regolith. Regolith contains silicon as an abundant element next to oxygen, and hence synthesis of silicon and its compounds seems pragmatic. Therefore, the objective of this study is to extract silicon carbide (SiC) from lunar regolith which has a wide range of applications in producing abrasives, electronics and ceramic components. The methodology involves heating the regolith to a high temperature so that volatile species such as Na, K, Fe, SiO are liberated and subsequently, the evolved SiO gases are reduced to SiC by using methane. This resulted in the formation of SiC whiskers which are verified by X-ray diffraction and Raman spectroscopy. Electron microscopy images reveal that the majority of the SiC whiskers are formed by vapor–liquid-solid mechanisms with diameters ranging from 0.3 to 2 µm. Detailed electron diffraction and microscopy studies reveal that the whiskers formed are single crystals having a core–shell structure containing SiC and SiO_x respectively. This study provides a foundation for the direct manufacturing of SiC whiskers from lunar regolith which can be used for fabricating electronic devices, construction materials, radiation shields and habitats on the surface of moon.

就地资源利用对于确保探索任务的可持续性非常重要，例如在月球上建立可居住的地外基地。在月球上建造建筑和制造产品必须利用月球表面可用的资源，如风化层。这需要从风化层中提取金属、金属合金和陶瓷等原材料。风土中除氧外还含有丰富的硅元素，因此硅及其化合物的合成似乎是可行的。因此，本研究的目的是从月球风化层中提取碳化硅（SiC），碳化硅在生产磨料、电子和陶瓷元件方面有着广泛的应用。该方法包括将风化层加热到高温，从而释放出挥发性物质，如Na， K, Fe, SiO，随后，通过使用甲烷，生成的SiO气体被还原为SiC。这导致了碳化硅晶须的形成，并通过x射线衍射和拉曼光谱进行了验证。电镜图像显示，大多数SiC晶须是由气液固机制形成的，直径在0.3 ~ 2 μ m之间。详细的电子衍射和显微镜研究表明，形成的晶须为单晶，具有核壳结构，分别含有SiC和SiOx。本研究为利用月壤直接制备碳化硅晶须奠定了基础，该晶须可用于制造电子器件、建筑材料、辐射屏蔽和月球表面栖息地。

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引用次数: 0

Elevated temperature structured light scanning for in situ monitoring of forging dies 锻模现场监测的高温结构光扫描

IF 2 Q3 ENGINEERING, MANUFACTURING

Manufacturing Letters

Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.051

Jake Dvorak, Tony Schmitz

Metrology grade structured light scanning has been established as an effective non-contact measurement method for dimensional analysis of complex components at standard temperatures. Initial efforts have demonstrated the use of custom structured light systems for measurements of forgings and at elevated temperature environments. However, little work has been done to evaluate the performance of metrology grade structured light systems at elevated temperatures. This paper provides a performance baseline for a commercially available ZEISS ATOS Q structured light system using a calibrated gage block at elevated temperatures. Results show that the measured length of the gage block matches that of simulated lengths using a temperature-dependent coefficient of thermal expansion taken from handbook data. These results motivate the use of structured light scanning for measurements in forging and other elevated temperature manufacturing applications.

计量级结构光扫描已成为标准温度下复杂部件尺寸分析的一种有效的非接触测量方法。最初的努力已经证明了使用定制的结构光系统来测量锻件和高温环境。然而，很少有研究对计量级结构光系统在高温下的性能进行评估。本文提供了一种商用蔡司ATOS Q结构光系统的性能基线，该系统使用在高温下校准的量块。结果表明，测量的量块长度与从手册数据中获得的热膨胀温度相关系数的模拟长度相匹配。这些结果激发了在锻造和其他高温制造应用中使用结构光扫描进行测量。

引用次数: 0