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Compensation of billet variabilities through metamodel-based optimization in open die forging 通过基于元模型的优化补偿开模锻造中的坯料变化
IF 3.4 3区 工程技术 Q1 Engineering Pub Date : 2024-03-22 DOI: 10.1007/s00170-024-13392-3

Abstract

Closed-die forging preforms are usually made by open die forging operations, which are subject to significant variabilities. A sensitivity study covering a wide range of influencing parameters has highlighted the predominant influence of the initial billet geometry. The forging die strokes were also highly influential, while their fidelity is sufficient to use them as control parameters in order to compensate the geometrical dispersions of the billet. Consequently, their optimization was performed by taking a nominal preform geometry as the target. Polynomial surrogate models have been constructed to enable real-time optimization. A specific preform was used as a demonstrator in this study, while the approach was generic. The surrogate models were built using data from finite element simulations, which were first validated with an experimental campaign. On the one hand, this approach introduced agility by allowing changes in the billet geometry, and on the other hand, it allowed individual customization of the specific route to each billet.

摘要 闭模锻造预型件通常是通过开模锻造操作制成的,而开模锻造操作具有很大的可变性。对各种影响参数进行的敏感性研究表明,初始坯料几何形状的影响最大。锻造模具冲程的影响也很大,但其保真度足以用作控制参数,以补偿坯料的几何分散。因此,以标称预成型几何形状为目标对其进行了优化。为了实现实时优化,我们建立了多项式代理模型。在这项研究中,使用了一个特定的瓶坯作为示范,而方法是通用的。代用模型是利用有限元模拟的数据建立的,并首先通过实验活动进行验证。一方面,这种方法允许改变坯料的几何形状,从而提高了灵活性;另一方面,它允许对每个坯料的具体路线进行个性化定制。
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引用次数: 0
An optimized calculation method of the grinding wheel profile for the helical flute forming grinding 螺旋槽成形磨削砂轮轮廓的优化计算方法
IF 3.4 3区 工程技术 Q1 Engineering Pub Date : 2024-03-22 DOI: 10.1007/s00170-024-13447-5
Lei Jiang, Zhihui Yang, Yong Li, Guofu Ding, Xin He

The forming grinding process is a crucial method for helical flute grinding of the end mill and screw tap, and the grinding wheel profile is the key to ensure the precision of the helical flute, which is constrained by the grinding wheel posture. However, the existing methods have some deficiencies such as the invalidity or uneven wear problems. In this paper, an optimized calculation method of the grinding wheel profile for the forming grinding of the helical flute is proposed, including the suitable grinding posture correspondingly. Firstly, the parametric models of the helical cutting edge and the helical flute surface are established. Secondly, the contact condition between the grinding wheel and the flute is deduced to calculate the grinding wheel profile by the envelop theory. Thirdly, an optimization method for grinding wheel profile is proposed, which could predict of the solution interval, avoid the profile intersection, and improve wear resistance. Finally, the method was verified by a series of simulations and experiments, and the results show that the method could meet the grinding precision requirements and expand the application range of forming grinding technology in helical flute.

成形磨削工艺是立铣刀和螺旋丝锥螺旋刃磨削的关键方法,而砂轮轮廓是保证螺旋刃精度的关键,它受到砂轮姿态的制约。然而,现有的方法存在一些缺陷,如无效或磨损不均匀等问题。本文提出了一种用于螺旋刃成形磨削的砂轮轮廓优化计算方法,包括相应的合适磨削姿势。首先,建立了螺旋切削刃和螺旋刃表面的参数模型。其次,通过包络理论推导出砂轮与刃口的接触条件,从而计算出砂轮轮廓。第三,提出了砂轮轮廓的优化方法,该方法可以预测求解区间,避免轮廓交叉,提高耐磨性。最后,通过一系列仿真和实验对该方法进行了验证,结果表明该方法可以满足磨削精度要求,扩大了螺旋刃成形磨削技术的应用范围。
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引用次数: 0
Failure-based design validation for effective repair of multi-metal additive manufacturing: the case of remanufacturable brake caliper 基于故障的设计验证,实现多金属增材制造的有效修复:可再制造制动钳案例
IF 3.4 3区 工程技术 Q1 Engineering Pub Date : 2024-03-21 DOI: 10.1007/s00170-024-13425-x
Nurhasyimah Abd Aziz, Lenggeswaran Elanggoven, Dzuraidah Abd Wahab, Nur Alia Shazmin Zakaria, Nadhira Fathiah Kamarulzaman, Nurfadzylah Awang

The inclusion of additive manufacturing (AM) as an automated repair method leads to a sustainable remanufacturing process, which is known as additive repair. Despite its potential in improving the efficiency of repair and restoration, additive repair remains in its infancy and requires a thorough investigation on part design and process parameters. The major concern raised in additive repair is the capability to create perfect bonding between two metals, which will affect the mechanical properties of the complete repaired part. Hence, performing evaluation from the beginning is crucial to validate the feasibility of the process through appropriate structural analysis and to obtain deformation and stress results. Brake caliper housing is selected as a remanufacturable component for case exemplary purposes. Prior to analysis, the potential damages and failures of the brake caliper component were initially evaluated through literature surveys and direct interviews with industry experts where two types of damages were identified, namely, cracks and broken or fractured parts. Then, the validation focuses on comparative analysis of two different conditions of the brake caliper housing: original, and repaired caliper model using finite element analysis in ANSYS. Results indicate that the strength of the repaired caliper model shows equal and higher strength compared with the original model. This result confirms that the repair process through AM can retain or improve the quality of the remanufactured brake caliper housing. Therefore, this paper provides a systematic framework for the evaluation of mechanical properties in multi-metal additive repair with the integration of failure analysis techniques.

将增材制造(AM)作为一种自动修复方法,可实现可持续的再制造过程,这就是增材修复。尽管增材制造具有提高维修和修复效率的潜力,但其仍处于起步阶段,需要对部件设计和工艺参数进行深入研究。添加剂修复的主要问题是能否在两种金属之间形成完美的结合,这将影响整个修复部件的机械性能。因此,从一开始就进行评估至关重要,以便通过适当的结构分析验证工艺的可行性,并获得变形和应力结果。本案例选择制动钳壳体作为可再制造部件进行示例。在分析之前,通过文献调查和与行业专家的直接访谈,初步评估了制动钳部件的潜在损坏和故障,确定了两种损坏类型,即裂纹和破损或断裂部件。然后,利用 ANSYS 的有限元分析对制动钳外壳的两种不同情况进行比较分析,即原始制动钳模型和修复后的制动钳模型。结果表明,修复后的制动钳模型与原始模型相比,强度相当且更高。这一结果证实,通过 AM 进行修复可以保持或提高再制造制动钳壳体的质量。因此,本文结合失效分析技术,为多金属添加剂修复中的机械性能评估提供了一个系统框架。
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引用次数: 0
Study on design of conical arc side-edge milling cutter and cutting performance under ultrasonic-assisted condition 锥形圆弧侧刃铣刀的设计及超声波辅助条件下的切削性能研究
IF 3.4 3区 工程技术 Q1 Engineering Pub Date : 2024-03-21 DOI: 10.1007/s00170-024-13423-z
Guangyue Wang, Wenyuan Xu, Chunhui Li, Jiaming Liu, Tao Chen

Ball-end milling cutters are commonly used in the finishing processes of curved-side milling for titanium alloys; however, several issues arise during machining, such as poor cutting conditions at the bottom of the end teeth, low cutting speeds, and limited chip space. Given the above issues, the research on the design and manufacture of conical arc side-edge milling cutter for titanium alloy processing was carried out in this paper; the mathematical model of the vital structure of conical arc side-edge milling cutter was established; the grinding trajectory equations of tool front and flank were deduced; the tool-workpiece kinematics of ultrasonic vibration applied to conical arc side edge was studied; and the comparative experimental study of the conical arc side-edge milling cutter cutting titanium alloy with and without ultrasonic vibration was carried out. The experiment results indicate that in comparison to conventional milling techniques, ultrasonic vibration cutting significantly decreases cutting force, plastic deformation of the chip, and wear rate of the flank face. The tool wear band is both longer and more uniform, bonding phenomena in titanium alloys are distinctly reduced, and tool performance is improved.

球头铣刀通常用于钛合金曲面铣削的精加工工序,但在加工过程中会出现端齿底部切削条件差、切削速度低、切屑空间有限等问题。针对上述问题,本文开展了钛合金加工用锥形圆弧侧刃铣刀的设计与制造研究,建立了锥形圆弧侧刃铣刀的重要结构数学模型,推导了刀具正面和侧面的磨削轨迹方程,研究了锥形圆弧侧刃施加超声波振动时刀具与工件的运动学特性,并对锥形圆弧侧刃铣刀切削钛合金时施加超声波振动与不施加超声波振动进行了对比实验研究。实验结果表明,与传统铣削技术相比,超声波振动切削可显著降低切削力、切屑塑性变形和侧刃磨损率。刀具磨损带更长、更均匀,钛合金中的粘结现象明显减少,刀具性能得到改善。
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引用次数: 0
Hybrid physics data-driven model-based fusion framework for machining tool wear prediction 基于混合物理数据驱动模型的加工刀具磨损预测融合框架
IF 3.4 3区 工程技术 Q1 Engineering Pub Date : 2024-03-21 DOI: 10.1007/s00170-024-13365-6
Tianhong Gao, Haiping Zhu, Jun Wu, Zhiqiang Lu, Shaowen Zhang

Accurate tool wear prediction is of great significance to improve production efficiency, ensure product quality and reduce machining cost. This paper proposes a hybrid physics data-driven model-based fusion framework for tool wear prediction to improve low prediction accuracy of physical model and poor interpretation of data-driven model. In this framework, physical information and local features of sensor measurement signals are used as inputs to build a hybrid physics data-driven (HPDD) model. And data mining and physics principles are effectively integrated by using unlabeled samples for data expansion. Piecewise prediction is introduced to reduce difficulty in parameter estimation. Then, in order to manage prediction uncertainty of physical information and HPDD method, two prediction results are gradually combined based on Bayesian fusion mechanism to eliminate prediction error. Finally, the effectiveness of the proposed method is verified by experiment. Compared with existing methods, this method significantly improves prediction. The mean values of root mean square error (RMSE) and mean relative error (MARE) for tool wear prediction results are respectively 2.28 and 1.85.

精确的刀具磨损预测对提高生产效率、保证产品质量和降低加工成本具有重要意义。本文提出了一种基于混合物理数据驱动模型的刀具磨损预测融合框架,以改善物理模型预测精度低和数据驱动模型解释能力差的问题。在该框架中,传感器测量信号的物理信息和局部特征被用作建立混合物理数据驱动(HPDD)模型的输入。通过使用无标记样本进行数据扩展,数据挖掘和物理原理得到了有效整合。引入分片预测以降低参数估计的难度。然后,为了管理物理信息和 HPDD 方法的预测不确定性,基于贝叶斯融合机制逐步合并两种预测结果,以消除预测误差。最后,实验验证了所提方法的有效性。与现有方法相比,该方法显著改善了预测效果。刀具磨损预测结果的均方根误差(RMSE)和平均相对误差(MARE)的平均值分别为 2.28 和 1.85。
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引用次数: 0
Research on efficient electrical discharge machining trepanning technology of TC4 titanium alloy hole TC4 钛合金孔的高效放电加工桁架技术研究
IF 3.4 3区 工程技术 Q1 Engineering Pub Date : 2024-03-21 DOI: 10.1007/s00170-024-13362-9
Mingbo Qiu, Entao Wu, Chuangchuang Guo, Zongxiu Yao, Jingtao Li, Yimiao Zhang, Zhidong Liu

Owing to low machining efficiency, poor machining accuracy, and surface quality in traditional electrical discharge machining (EDM) of TC4 titanium alloy holes, an EDM trepanning method was developed using a deionized water medium and a flushing liquid in tube electrodes (denoted by EDM-TFD). Several experiments and research mechanisms were conducted on EDM-TFD. Compared with traditional EDM, ED milling, and EDM trepanning, EDM-TFD featured increased hole machining efficiency by more than five times, improved machining taper by more than 57%, and improved surface quality by more than 40%. The optimal processing technology was determined through process experiments using copper tube electrodes, a flushing liquid with a speed of 2 m/s, pulse width (Ton) of 150 μs, pulse interval (Toff) of 150 μs, and peak current (Ip) of 15 A. Under the optimized process, the hole exhibited a feed rate of 1.1 mm/min, machining efficiency of 38 mm3/min, machining taper of 40 μm, and surface roughness of 5.2 μm.

由于传统的 TC4 钛合金孔放电加工(EDM)存在加工效率低、加工精度和表面质量差的问题,因此开发了一种在管状电极中使用去离子水介质和冲洗液的 EDM 穿孔方法(简称 EDM-TFD)。对 EDM-TFD 进行了多次实验和研究。与传统的电火花加工、电火花铣削和电火花穿孔相比,EDM-TFD 的孔加工效率提高了 5 倍以上,加工锥度提高了 57% 以上,表面质量提高了 40% 以上。通过使用铜管电极、速度为 2 m/s 的冲洗液、150 μs 的脉冲宽度 (Ton)、150 μs 的脉冲间隔 (Toff) 和 15 A 的峰值电流 (Ip)进行工艺实验,确定了最佳加工技术。在优化工艺下,孔的进给速度为 1.1 mm/min,加工效率为 38 mm3/min,加工锥度为 40 μm,表面粗糙度为 5.2 μm。
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引用次数: 0
Automated robotic assembly of shaft sleeve based on reinforcement learning 基于强化学习的轴套自动装配机器人
IF 3.4 3区 工程技术 Q1 Engineering Pub Date : 2024-03-21 DOI: 10.1007/s00170-024-13467-1
Xumiao Ma, De Xu

Shaft sleeve assembly is a common task in industrial manufacturing. The fitting approach for shaft sleeve assembly is usually interference fit, which requires significant contact forces. Conventional assembly methods, though focused on safety, often struggle to achieve high efficiency. Reinforcement learning can effectively select appropriate assembly actions through interaction with the environment, making it well-suited for shaft sleeve assembly tasks. Firstly, a comprehensive workflow for shaft sleeve assembly is formulated, including system initialization, insertion, push, and completion. Our research focuses mainly on the insertion process. Secondly, the core control algorithm adopts a deep reinforcement learning method based on the Actor-Critic architecture. The reward function includes safety reward, step length reward, and step reward. Safety reward ensures assembly security, while step length and step reward enhance assembly efficiency from different perspectives. Finally, real-world experiments on shaft sleeve assembly are conducted, including ablation experiments, parameter tuning experiments on reward function, and comparative experiments with conventional methods. The results of the ablation experiments and parameter tuning experiments indicate that after combining safety reward, step length reward, and step reward, the assembly effect achieves the best, verifying the effectiveness of the proposed reward function. Comparative experimental results demonstrate that our approach not only enhances safety compared to conventional methods but also significantly improves assembly efficiency, indicating the feasibility of this method.

轴套装配是工业制造中的一项常见任务。轴套装配的配合方法通常是过盈配合,需要很大的接触力。传统的装配方法虽然注重安全性,但往往难以实现高效率。强化学习可以通过与环境的交互有效地选择适当的装配动作,因此非常适合轴套装配任务。首先,制定了轴套装配的综合工作流程,包括系统初始化、插入、推动和完成。我们的研究主要集中在插入过程。其次,核心控制算法采用了基于行为批判架构的深度强化学习方法。奖励函数包括安全奖励、步长奖励和步长奖励。安全奖励确保了装配安全,而步长奖励和步数奖励则从不同角度提高了装配效率。最后,进行了轴套装配的实际实验,包括烧蚀实验、奖励函数的参数调整实验以及与传统方法的对比实验。烧蚀实验和参数调整实验的结果表明,将安全奖励、步长奖励和阶跃奖励相结合后,装配效果最佳,验证了所提出的奖励函数的有效性。对比实验结果表明,与传统方法相比,我们的方法不仅增强了安全性,还显著提高了装配效率,说明这种方法是可行的。
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引用次数: 0
A fast simulation method for thermal management in wire arc additive manufacturing repair of a thin-walled structure 线弧增材制造薄壁结构修复热管理的快速模拟方法
IF 3.4 3区 工程技术 Q1 Engineering Pub Date : 2024-03-21 DOI: 10.1007/s00170-024-13427-9
Paul Qvale, Eirik B. Njaastad, Torgeir Bræin, Xiaobo Ren

Ensuring first-time-right on-site repair of critical structures is a key challenge for additive manufacturing (AM)–based repair solutions. Fast thermal simulations are thus needed to plan efficient and error-free AM processes. This paper addresses a fast thermal simulation method for a novel subsea wire arc additive manufacturing (SWAAM) repair procedure. Current commercial finite element (FE) codes for typical welding and AM are computationally expensive and slow. The presented 2D finite difference approach can be used to simulate SWAAM on a damaged plate with around 70 times acceleration compared to real welding times, without the use of parallelization. Although not being able to accurately represent the temperature in close vicinity of the welding torch, the approach shows excellent correspondence with FE simulations and experiments in regions of the plate where the temperature has assumed a distribution that is largely two-dimensional. Compared with FE simulations, the approach is experimentally verified to be accurate to 10 °C within 7 s after the welding torch has passed a point on the plate. Thus, the approach can provide a measure of the global temperature field in a thin-walled structure during repair. The thermal simulation is preceded by a welding path planner, which generates appropriate paths based on slicing of a 3D surface scan of the damage that is to be repaired. Damages to equipment or non-ideal welding conditions are prevented by automatically pausing the welding if the calculated temperature in the path ahead of the welding torch exceeds a predefined interpass temperature limit.

确保第一时间对关键结构进行正确的现场修复,是基于快速成型制造(AM)的修复解决方案所面临的主要挑战。因此,需要进行快速热模拟,以规划高效、无差错的快速成型工艺。本文探讨了一种新型海底线弧快速成型制造(SWAAM)修复过程的快速热模拟方法。目前用于典型焊接和 AM 的商用有限元 (FE) 代码计算成本高且速度慢。所介绍的二维有限差分方法可用于模拟受损板材上的 SWAAM,与实际焊接时间相比,速度加快了约 70 倍,且无需使用并行化。虽然该方法无法准确表示焊枪附近的温度,但在温度分布基本为二维的板材区域,该方法与有限元模拟和实验显示出极佳的对应性。经实验验证,与有限元模拟相比,该方法可在焊枪通过板上某点后 7 秒内精确到 10 °C。因此,该方法可以测量维修过程中薄壁结构的整体温度场。在进行热模拟之前,需要先进行焊接路径规划,根据待修复损伤的三维表面扫描切片生成合适的路径。如果焊枪前方路径上的计算温度超过预先设定的通过间温度限制,则会自动暂停焊接,从而防止设备损坏或焊接条件不理想。
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引用次数: 0
Adaptive location method for film cooling holes based on the design intent of the turbine blade 基于涡轮叶片设计意图的薄膜冷却孔自适应定位方法
IF 3.4 3区 工程技术 Q1 Engineering Pub Date : 2024-03-21 DOI: 10.1007/s00170-024-13456-4

Abstract

Due to the inevitable deviation of the casting process, the dimensional error of the turbine blade is introduced. As a result, the location datum of the film cooling holes is changed, which has an impact on the machining accuracy. The majority of pertinent studies concentrate on the rigid location approach for the entire blade, which results in a modest relative position error of the blade surface but still fails to give the exact position and axial direction of the film cooling holes of the deformed blade. In this paper, the entire deformation of the blade cross-section curve is divided into a number of deformation combinations of the mean line curve based on the construction method of the blade design intent. The exact location of the film cooling holes in the turbine blade with deviation is therefore efficiently solved by a flexible deformation of the blade that optimises the position and axial direction of the holes. The verification demonstrates that the novel method can significantly reduce both the contour deviation of the blade surface and the location issue of the film cooling holes. After machining experiments, the maximum position deviation of the holes is reduced by approximately 80% compared to the rigid location method of the entire blade, and the average value and standard deviation are also decreased by about 70%.

摘要 由于铸造过程中不可避免的偏差,涡轮叶片会产生尺寸误差。因此,薄膜冷却孔的位置基准会发生变化,从而影响加工精度。大多数相关研究都集中在整个叶片的刚性定位方法上,这种方法虽然能减小叶片表面的相对位置误差,但仍无法给出变形叶片上薄膜冷却孔的准确位置和轴向方向。本文根据叶片设计意图的构造方法,将整个叶片截面曲线的变形分为若干平均线曲线的变形组合。因此,通过对叶片进行柔性变形,优化孔的位置和轴向方向,就能有效解决涡轮叶片上薄膜冷却孔的准确位置偏差问题。验证结果表明,新方法可以显著减少叶片表面轮廓偏差和薄膜冷却孔的位置问题。经过加工实验,与整个叶片的刚性定位方法相比,孔的最大位置偏差减少了约 80%,平均值和标准偏差也减少了约 70%。
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引用次数: 0
Evaluation of energy consumption and carbon emission in EDM 评估电火花成形加工的能耗和碳排放
IF 3.4 3区 工程技术 Q1 Engineering Pub Date : 2024-03-21 DOI: 10.1007/s00170-024-13469-z

Abstract

Green manufacturing is one of the most important development directions in mechanical processing field. Electrical discharge machining (EDM), one of the non-traditional machining, is increasingly used. However, there were hardly any studies on the evaluation of energy consumption and carbon emissions in EDM. In this study, a quantitative assessment model of carbon emission in EDM was built based on the emission factor method. The tool electrode wear, harmless treatment of residual tool electrodes and working fluid, and electrical energy consumed by the equipment were considered in this assessment model. EDM drilling experiments were conducted to verify the effectiveness of the proposed model. The effects of pulse width, pulse interval, and peak current on machining time, surface roughness, energy consumption, and carbon emissions were analyzed. The CNC system, cooling system, and power supply consumed about 95% of the total energy. In small hole EDM drilling, the total carbon emissions from the preparation and waste residue treatment of workpiece and tool electrode were almost negligible due to the small material removal volume. The carbon emissions generated by electrical energy consumption account for about 50% of the total carbon emissions. Carbon emissions can be minimized to 72 g and energy consumption can be reduced to a minimum of 37.48 Wh when processing a small hole with the diameter of 1 mm and the depth of 6 mm by EDM drilling.

摘要 绿色制造是机械加工领域最重要的发展方向之一。电火花加工(EDM)作为非传统加工的一种,其应用日益广泛。然而,几乎没有关于电火花加工能耗和碳排放评估的研究。本研究基于排放因子法,建立了电火花加工碳排放的定量评估模型。该评估模型考虑了工具电极磨损、残余工具电极和工作液的无害化处理以及设备消耗的电能。为验证所提模型的有效性,进行了放电加工钻孔实验。分析了脉冲宽度、脉冲间隔和峰值电流对加工时间、表面粗糙度、能耗和碳排放的影响。数控系统、冷却系统和电源消耗了总能耗的 95%。在小孔电火花加工中,由于材料去除量较小,工件和工具电极的制备和废渣处理产生的碳排放总量几乎可以忽略不计。电能消耗产生的碳排放量约占总碳排放量的 50%。通过电火花钻孔加工直径为 1 毫米、深度为 6 毫米的小孔时,碳排放量可降至 72 克,能耗可降至最低 37.48 Wh。
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引用次数: 0
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International Journal of Advanced Manufacturing Technology
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