{"title":"Editorial for JSME Special Issue on Physics-Informed Machine Learning for Advanced Manufacturing","authors":"Y.B. Guo","doi":"10.1115/1.4065694","DOIUrl":"https://doi.org/10.1115/1.4065694","url":null,"abstract":"","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141365436","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Sidi Deng, Yongxian Zhu, Daniel R. Cooper, John W. Sutherland
Aluminum is the world's second most consumed metal, and its production contributes substantially to global greenhouse gas (GHG) emissions. When formulating decarbonization strategies, it is imperative to ensure their coherence and alignment with existing industrial practices and standards. A material flow analysis (MFA) is needed to gain a holistic and quantitative understanding of the flows and stocks of products/materials associated with all participants within the supply chain. To support risk-informed decision policymaking in decarbonizing aluminum manufacturing, this study develops a dynamic system model that maps global aluminum flows and computes their embedded GHG emissions. A baseline scenario is devised to reflect the current business and operation landscape, and three decarbonization strategies are proposed. Deterministic simulation is performed to generate dynamic material flows and performance metrics. Monte Carlo simulation is then implemented to evaluate the robustness of the system's performance under demand uncertainties. The results reveal the immense carbon implications of material efficiency, as well as the preponderant role of post-consumer scrap recycling in decarbonizing aluminum manufacturing. Informed by simulation outputs, macro decarbonization guidelines are formulated for various criteria. The object-oriented programming framework that underlies the dynamic MFA may be integrated with network analysis, agent-based simulation, and geospatial interfaces, which may lay the foundation for modeling more fine-grained material flows and supply chain structures.
{"title":"A Dynamic Material Flow Model for Risk-Informed Decision Making in Decarbonizing Global Aluminum Manufacturing","authors":"Sidi Deng, Yongxian Zhu, Daniel R. Cooper, John W. Sutherland","doi":"10.1115/1.4065695","DOIUrl":"https://doi.org/10.1115/1.4065695","url":null,"abstract":"\u0000 Aluminum is the world's second most consumed metal, and its production contributes substantially to global greenhouse gas (GHG) emissions. When formulating decarbonization strategies, it is imperative to ensure their coherence and alignment with existing industrial practices and standards. A material flow analysis (MFA) is needed to gain a holistic and quantitative understanding of the flows and stocks of products/materials associated with all participants within the supply chain. To support risk-informed decision policymaking in decarbonizing aluminum manufacturing, this study develops a dynamic system model that maps global aluminum flows and computes their embedded GHG emissions. A baseline scenario is devised to reflect the current business and operation landscape, and three decarbonization strategies are proposed. Deterministic simulation is performed to generate dynamic material flows and performance metrics. Monte Carlo simulation is then implemented to evaluate the robustness of the system's performance under demand uncertainties. The results reveal the immense carbon implications of material efficiency, as well as the preponderant role of post-consumer scrap recycling in decarbonizing aluminum manufacturing. Informed by simulation outputs, macro decarbonization guidelines are formulated for various criteria. The object-oriented programming framework that underlies the dynamic MFA may be integrated with network analysis, agent-based simulation, and geospatial interfaces, which may lay the foundation for modeling more fine-grained material flows and supply chain structures.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141366540","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Wire Arc Directed Energy Deposition (Wire Arc DED) has become a popular metal additive manufacturing technique for its capability to print large metal parts at a high deposition rate while being economically efficient. However, the Wire Arc DED process exhibits geometric inaccuracies resulting from the variability in the bead geometry and demonstrates heterogeneity in microstructure and mechanical properties. This study investigates the use of tailored periodic machining interventions during the Wire Arc DED process to address these shortcomings. The as-built geometry and surface finish, microstructure, and microhardness of multi-layer wall structures produced with and without machining interventions carried out at different temperatures are compared. The machining interventions are found to reduce the uncertainty in bead geometry evolution and significantly improve the surface roughness of the as-built walls, thus reducing the need for further post-processing of the wall surfaces. Although the microstructure constituents of the as-built wall structures with and without machining interventions are similar, the machining interventions result in finer grains in the interior of the part. Machining interventions are found to yield a statistically significant increase in microhardness, indicating increased strength compared to Wire Arc DED alone. In addition, the spread of the microhardness distribution is reduced in Hybrid-Wire Arc DED, indicating improved homogeneity of the grain size distribution compared to Wire Arc DED alone. The study shows that the proposed hybrid manufacturing technique has the potential to control and improve the geometric and mechanical properties of additively manufactured metal components.
线弧定向能量沉积（Wire Arc Directed Energy Deposition，Wire Arc DED）能够以较高的沉积速率打印大型金属零件，同时具有较高的经济效益，因此已成为一种流行的金属增材制造技术。然而，线弧定向能沉积工艺因珠子几何形状的变化而导致几何误差，并表现出微观结构和机械性能的异质性。本研究探讨了在线弧去毛刺工艺中使用定制的周期性加工干预来解决这些缺陷。比较了在不同温度下进行和未进行加工干预的多层壁结构的竣工几何形状、表面光洁度、微观结构和显微硬度。结果发现，加工干预可减少珠状几何形状演变的不确定性，并显著改善坯壁的表面粗糙度，从而减少对坯壁表面进行进一步后处理的需要。虽然有加工干预和没有加工干预的坯壁结构的微观结构成分相似，但加工干预会使零件内部的晶粒更细。经统计发现，加工干预可显著提高显微硬度，这表明与单独的线弧去毛刺相比，加工干预可提高强度。此外，混合-线弧去毛刺工艺中的显微硬度分布范围缩小，表明与单独的线弧去毛刺工艺相比，晶粒尺寸分布的均匀性得到改善。这项研究表明，所提出的混合制造技术具有控制和改善快速成型金属部件的几何和机械性能的潜力。
{"title":"Effect of Interlayer Machining Interventions on the Geometric and Mechanical Properties of Wire Arc Directed Energy Deposition Parts","authors":"Asif Rashid, Akshar Kota, Denis Boing, S. Melkote","doi":"10.1115/1.4065577","DOIUrl":"https://doi.org/10.1115/1.4065577","url":null,"abstract":"\u0000 Wire Arc Directed Energy Deposition (Wire Arc DED) has become a popular metal additive manufacturing technique for its capability to print large metal parts at a high deposition rate while being economically efficient. However, the Wire Arc DED process exhibits geometric inaccuracies resulting from the variability in the bead geometry and demonstrates heterogeneity in microstructure and mechanical properties. This study investigates the use of tailored periodic machining interventions during the Wire Arc DED process to address these shortcomings. The as-built geometry and surface finish, microstructure, and microhardness of multi-layer wall structures produced with and without machining interventions carried out at different temperatures are compared. The machining interventions are found to reduce the uncertainty in bead geometry evolution and significantly improve the surface roughness of the as-built walls, thus reducing the need for further post-processing of the wall surfaces. Although the microstructure constituents of the as-built wall structures with and without machining interventions are similar, the machining interventions result in finer grains in the interior of the part. Machining interventions are found to yield a statistically significant increase in microhardness, indicating increased strength compared to Wire Arc DED alone. In addition, the spread of the microhardness distribution is reduced in Hybrid-Wire Arc DED, indicating improved homogeneity of the grain size distribution compared to Wire Arc DED alone. The study shows that the proposed hybrid manufacturing technique has the potential to control and improve the geometric and mechanical properties of additively manufactured metal components.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-05-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141115984","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Fengfeng Zhou, Xingyu Fu, Siying Chen, Changheon Han, M. Jun
Wafer quality control is one of the important processes to improve the yield rate of semiconductor products. Profile quality and defects in the wafer are two key factors that should be taken into consideration. In this research, we introduce a method that measures the profile of the upper surface and the thickness of the wafer at the same time using an optical fiber cascaded Fabry-Pérot interferometer working at wavelength of 1550 nm. Therefore, the 3D profile of the wafer can be reconstructed directly. Testing results show that both accuracy and precision of the Fabry-Pérot interferometer are within a nanometer scale. Defects, especially those embedded inside the wafer, will be detected by monitoring the leaky field with treating wafers as slab waveguides. With the leaky field detection, defects on the lower surface of the wafer were successfully detected by monitoring the leaky field above the upper surface of the wafer. Compared with traditional methods such as radiographic testing (RT) or computed tomography (CT) testing, the proposed methods provide a cost-effective alternative for wafer quality evaluation.
{"title":"3D Profile Reconstruction and Internal Defect Detection of Silicon Wafers Using Cascaded Fiber Optic Fabry-Pérot Interferometer and Leaky Field Detection Technologies","authors":"Fengfeng Zhou, Xingyu Fu, Siying Chen, Changheon Han, M. Jun","doi":"10.1115/1.4065523","DOIUrl":"https://doi.org/10.1115/1.4065523","url":null,"abstract":"\u0000 Wafer quality control is one of the important processes to improve the yield rate of semiconductor products. Profile quality and defects in the wafer are two key factors that should be taken into consideration. In this research, we introduce a method that measures the profile of the upper surface and the thickness of the wafer at the same time using an optical fiber cascaded Fabry-Pérot interferometer working at wavelength of 1550 nm. Therefore, the 3D profile of the wafer can be reconstructed directly. Testing results show that both accuracy and precision of the Fabry-Pérot interferometer are within a nanometer scale. Defects, especially those embedded inside the wafer, will be detected by monitoring the leaky field with treating wafers as slab waveguides. With the leaky field detection, defects on the lower surface of the wafer were successfully detected by monitoring the leaky field above the upper surface of the wafer. Compared with traditional methods such as radiographic testing (RT) or computed tomography (CT) testing, the proposed methods provide a cost-effective alternative for wafer quality evaluation.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140972222","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Kaveh Rahimzadeh Berenji, Faraz Tehranizadeh, Erhan Budak
As the industry seeks better quality and efficiency, multitasking machine tools are becoming increasingly popular owing to their ability to create complex parts in one setup. Turn-milling, a type of multi-axis machining, combines milling and turning processes to remove material through simultaneous rotations of the cutter and workpiece with the translational feed of the tool. While turn-milling can be advantageous for large parts made of hard-to-cut materials, it also offers challenges in terms of surface form errors and process stability. Because tool eccentricity and workpiece rotation lead to more complexity in process mechanics and dynamics, traditional milling stability models cannot predict the stability of turn-milling processes. This study presents a mathematical model based on process mechanics and dynamics by incorporating the unique characteristics of the orthogonal turn-milling process to avoid self-excited chatter vibrations. A novel approach was employed to model time-varying delays considering the simultaneous rotation of the tool and workpiece. Stability analysis of the system was performed in both the semi-discrete time and frequency domains. The effects of eccentricity and workpiece speed on stability diagrams were demonstrated and validated through experiments. The results show that the tool eccentricity and workpiece speed alter the engagement geometry and delay in the regeneration mechanism, respectively, leading to significant stability diagram alterations. The proposed approach offers a comprehensive framework for the stability of orthogonal turn-milling and guidance for the selection of process conditions to achieve stable cuts with enhanced productivity.
{"title":"Chatter Stability of Orthogonal Turn-Milling Process in Frequency and Discrete-Time Domains","authors":"Kaveh Rahimzadeh Berenji, Faraz Tehranizadeh, Erhan Budak","doi":"10.1115/1.4065485","DOIUrl":"https://doi.org/10.1115/1.4065485","url":null,"abstract":"\u0000 As the industry seeks better quality and efficiency, multitasking machine tools are becoming increasingly popular owing to their ability to create complex parts in one setup. Turn-milling, a type of multi-axis machining, combines milling and turning processes to remove material through simultaneous rotations of the cutter and workpiece with the translational feed of the tool. While turn-milling can be advantageous for large parts made of hard-to-cut materials, it also offers challenges in terms of surface form errors and process stability. Because tool eccentricity and workpiece rotation lead to more complexity in process mechanics and dynamics, traditional milling stability models cannot predict the stability of turn-milling processes. This study presents a mathematical model based on process mechanics and dynamics by incorporating the unique characteristics of the orthogonal turn-milling process to avoid self-excited chatter vibrations. A novel approach was employed to model time-varying delays considering the simultaneous rotation of the tool and workpiece. Stability analysis of the system was performed in both the semi-discrete time and frequency domains. The effects of eccentricity and workpiece speed on stability diagrams were demonstrated and validated through experiments. The results show that the tool eccentricity and workpiece speed alter the engagement geometry and delay in the regeneration mechanism, respectively, leading to significant stability diagram alterations. The proposed approach offers a comprehensive framework for the stability of orthogonal turn-milling and guidance for the selection of process conditions to achieve stable cuts with enhanced productivity.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140999085","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Warm forming holds significant potential in shaping difficult-to-form materials due to the comprehensive advantages compared to the cold and hot forming. Effective heating is essential for specific warm forming processes. This paper investigated a novel warm air bending technique using an online local contact heating method. Preheating stage heat transfer and air bending of AZ31B sheets were examined at temperatures ranging from room temperature to 300 °C by experiments and finite element analysis considering the thermomechanical coupling effect. A noteworthy augmentation in the bending center angle, progressing from 86° to 133°, was obtained as the heating temperature ascends from room temperature to 250 °C. Fractures were successfully eliminated when the heating temperatures of the sheets exceed 150 °C. As the heating temperature increases, a concurrent decrease in the rebound angle is observed, diminishing from 10.6° to 2.3°. The results confirm the feasibility of warm air bending using the online local contact heating in the application in industrial environment, in terms of forming quality and production efficiency. Keywords: warm forming, air bending; contact heating, thermomechanical coupling analysis, AZ31B
{"title":"Warm air bending of AZ31B sheets based on an online local contact heating method","authors":"Xu Wang, Tong Wen, Feng Liu, Yin Zhou","doi":"10.1115/1.4065484","DOIUrl":"https://doi.org/10.1115/1.4065484","url":null,"abstract":"\u0000 Warm forming holds significant potential in shaping difficult-to-form materials due to the comprehensive advantages compared to the cold and hot forming. Effective heating is essential for specific warm forming processes. This paper investigated a novel warm air bending technique using an online local contact heating method. Preheating stage heat transfer and air bending of AZ31B sheets were examined at temperatures ranging from room temperature to 300 °C by experiments and finite element analysis considering the thermomechanical coupling effect. A noteworthy augmentation in the bending center angle, progressing from 86° to 133°, was obtained as the heating temperature ascends from room temperature to 250 °C. Fractures were successfully eliminated when the heating temperatures of the sheets exceed 150 °C. As the heating temperature increases, a concurrent decrease in the rebound angle is observed, diminishing from 10.6° to 2.3°. The results confirm the feasibility of warm air bending using the online local contact heating in the application in industrial environment, in terms of forming quality and production efficiency. Keywords: warm forming, air bending; contact heating, thermomechanical coupling analysis, AZ31B","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140998754","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Process Capability Indices (PCIs) are major tools in Geometric Dimensioning & Tolerancing (GD&T) for quantifying the production quality, monitoring production or prioritizing projects. Initially, PCIs were constructed for studying each characteristic of the process independently. Then, they have been extended to analyze several dependent characteristics simultaneously. Nowadays, with the increasing complexity of the production parts, for example in aircraft engines, the conformity of one part may rely on the conformity of hundreds of characteristics. Moreover, those characteristics being dependent, it may be misleading to make decisions only based on univariate PCIs. However, classical multivariate PCIs in the literature do not allow treating such amount of data efficiently, unless assuming Gaussian distribution, which is not always true. Regarding those issues, we advocate for PCIs based on some transformation of the conformity rates. This presents the advantage of being free from distributional assumptions, such as the Gaussian distribution. In addition, it has direct interpretation, allowing it to compare different processes. To estimate the PCIs of parts with hundreds of characteristics, we propose to use Vine Copulas. This is a very flexible class of models, which gives precise estimation even in high dimension. From an industrial perspective, the computation of the estimator can be costly. To answer this point, we explain how to compute a lower bound of the proposed PCI, which is faster to calculate. We illustrate our method adaptability with simulations under Gaussian and non-Gaussian distributions. We apply it to compare the production of Fan Blades of two different factories.
{"title":"Non-Gaussian Multivariate Process Capability Based on the Copulas Method: An Application to Aircraft Engine Fan Blades","authors":"Cyprien Ferraris, Mohamed Achibi","doi":"10.1115/1.4065456","DOIUrl":"https://doi.org/10.1115/1.4065456","url":null,"abstract":"\u0000 Process Capability Indices (PCIs) are major tools in Geometric Dimensioning & Tolerancing (GD&T) for quantifying the production quality, monitoring production or prioritizing projects. Initially, PCIs were constructed for studying each characteristic of the process independently. Then, they have been extended to analyze several dependent characteristics simultaneously. Nowadays, with the increasing complexity of the production parts, for example in aircraft engines, the conformity of one part may rely on the conformity of hundreds of characteristics. Moreover, those characteristics being dependent, it may be misleading to make decisions only based on univariate PCIs. However, classical multivariate PCIs in the literature do not allow treating such amount of data efficiently, unless assuming Gaussian distribution, which is not always true. Regarding those issues, we advocate for PCIs based on some transformation of the conformity rates. This presents the advantage of being free from distributional assumptions, such as the Gaussian distribution. In addition, it has direct interpretation, allowing it to compare different processes. To estimate the PCIs of parts with hundreds of characteristics, we propose to use Vine Copulas. This is a very flexible class of models, which gives precise estimation even in high dimension. From an industrial perspective, the computation of the estimator can be costly. To answer this point, we explain how to compute a lower bound of the proposed PCI, which is faster to calculate. We illustrate our method adaptability with simulations under Gaussian and non-Gaussian distributions. We apply it to compare the production of Fan Blades of two different factories.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-05-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141015015","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Surface roughness is a critical indicator to evaluate the quality of ground surfaces for 4H-SiC. Determining surface roughness experimentally is a time-consuming and laborious process, and developing a reliable model for predicting surface roughness is a key challenge in 4H-SiC grinding. However, the existing models for surface roughness in wafer rotational grinding fail to yield reasonable results because they do not adequately consider the processing parameters and material characteristics. In this study, a new analytical model for surface roughness in 4H-SiC wafer rotational grinding is proposed, which comprehensively incorporates the grinding conditions and material characteristics of brittle substrate. This model derives and calculates the material's elastic recovery coefficient based on contact mechanics and elastic contact theory. Subsequently, we modified the grain depth-of-cut model by incorporating elastic recovery coefficient. Additionally, we considered the co-existing of machining-induced ductility and brittleness of the substrate surface under random grain depth-of-cut distribution that conforms to the Rayleigh distribution. To validate the accuracy of the proposed model, a series of grinding experiments are conducted using various grain depth-of-cut to produce 4H-SiC wafers with different surface roughness values. These results are then compared with those predicted by both the proposed model and the existing models. The findings demonstrate that the predictions obtained from the proposed model exhibit better agreement with the experimental results. This research addresses the need for an improved surface roughness model in 4H-SiC wafer rotational grinding.
{"title":"Surface Roughness Model of Ground 4H-SiC Considering Ductile and Brittle Removal","authors":"Hongyi Xiang, Haoxiang Wang, Renke Kang, Shang Gao","doi":"10.1115/1.4065455","DOIUrl":"https://doi.org/10.1115/1.4065455","url":null,"abstract":"\u0000 Surface roughness is a critical indicator to evaluate the quality of ground surfaces for 4H-SiC. Determining surface roughness experimentally is a time-consuming and laborious process, and developing a reliable model for predicting surface roughness is a key challenge in 4H-SiC grinding. However, the existing models for surface roughness in wafer rotational grinding fail to yield reasonable results because they do not adequately consider the processing parameters and material characteristics. In this study, a new analytical model for surface roughness in 4H-SiC wafer rotational grinding is proposed, which comprehensively incorporates the grinding conditions and material characteristics of brittle substrate. This model derives and calculates the material's elastic recovery coefficient based on contact mechanics and elastic contact theory. Subsequently, we modified the grain depth-of-cut model by incorporating elastic recovery coefficient. Additionally, we considered the co-existing of machining-induced ductility and brittleness of the substrate surface under random grain depth-of-cut distribution that conforms to the Rayleigh distribution. To validate the accuracy of the proposed model, a series of grinding experiments are conducted using various grain depth-of-cut to produce 4H-SiC wafers with different surface roughness values. These results are then compared with those predicted by both the proposed model and the existing models. The findings demonstrate that the predictions obtained from the proposed model exhibit better agreement with the experimental results. This research addresses the need for an improved surface roughness model in 4H-SiC wafer rotational grinding.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-05-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141016728","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
A novel co-extrusion system for continuous fiber reinforced thermoplastic composites in filament and narrow tape format was designed, fabricated, and tested. The new modified pultrusion process, called In Situ Impregnation, impregnates continuous dry fiber reinforcement tows in-situ with thermoplastic matrix for applications ranging from 3D printing using robotic manipulation to automated fiber placement. The technical goal of the system is to directly co-extrude and impregnate a reinforcement fiber tow (carbon) with thermoplastic matrix injected by an extruder fed with thermoplastic pellets. This approach uses inexpensive materials instead of ‘prepreg’ tow in order to streamline the additive manufacturing process, cut costs for advanced composites manufacturing, and deliver fully customizable fiber orientation. The purpose of this paper is to discuss analytical modeling of friction and fiber tensioning in the system which allows for the full impregnation of the fibers. Experiments were conducted on a working pultrusion system where load was adjusted through the tensioning system to better understand the amount of friction throughout the system, the magnitude of tension in the fiber tow, and to validate the models. The resulting friction model can be used by machine designers to estimate the tension in tows, ropes, fibers, etc. in similar tensioning devices, and estimate automated system specifications such as motor requirements. A brief description of the new manufacturing process is also provided. Future work includes commercialization of the technology, automation of the manufacturing system, and further modeling work to predict fiber spreading behavior based on geometric factors.
我们设计、制造并测试了一种用于长丝和窄带形式连续纤维增强热塑性复合材料的新型共挤系统。这种新型改良拉挤工艺称为 "原位浸渍"（In Situ Impregnation），可将连续干纤维增强丝束与热塑性基体原位浸渍，应用范围从使用机器人操作的 3D 打印到自动纤维铺放。该系统的技术目标是直接将增强纤维丝束（碳纤维）与由挤出机注入热塑性塑料颗粒的热塑性基质进行共挤出和浸渍。这种方法使用廉价材料代替 "预浸料 "丝束，以简化增材制造工艺，降低先进复合材料制造成本，并提供完全可定制的纤维取向。本文旨在讨论该系统中摩擦和纤维张力的分析建模，以实现纤维的完全浸渍。实验是在一个工作中的拉挤系统上进行的，通过拉伸系统调整负载，以更好地了解整个系统中的摩擦力大小、纤维束中的张力大小，并对模型进行验证。由此产生的摩擦模型可供机器设计人员用于估算类似拉伸装置中纤维束、绳索、纤维等的张力，以及估算电机要求等自动化系统规格。此外，还简要介绍了新的制造工艺。未来的工作包括技术的商业化、制造系统的自动化，以及根据几何因素预测纤维铺展行为的进一步建模工作。
{"title":"An Analytical Friction Model for Handling and Spreading of Carbon Fiber Tows for Composite Prepregging Applications","authors":"J. Garofalo, D. Walczyk","doi":"10.1115/1.4065410","DOIUrl":"https://doi.org/10.1115/1.4065410","url":null,"abstract":"\u0000 A novel co-extrusion system for continuous fiber reinforced thermoplastic composites in filament and narrow tape format was designed, fabricated, and tested. The new modified pultrusion process, called In Situ Impregnation, impregnates continuous dry fiber reinforcement tows in-situ with thermoplastic matrix for applications ranging from 3D printing using robotic manipulation to automated fiber placement. The technical goal of the system is to directly co-extrude and impregnate a reinforcement fiber tow (carbon) with thermoplastic matrix injected by an extruder fed with thermoplastic pellets. This approach uses inexpensive materials instead of ‘prepreg’ tow in order to streamline the additive manufacturing process, cut costs for advanced composites manufacturing, and deliver fully customizable fiber orientation. The purpose of this paper is to discuss analytical modeling of friction and fiber tensioning in the system which allows for the full impregnation of the fibers. Experiments were conducted on a working pultrusion system where load was adjusted through the tensioning system to better understand the amount of friction throughout the system, the magnitude of tension in the fiber tow, and to validate the models. The resulting friction model can be used by machine designers to estimate the tension in tows, ropes, fibers, etc. in similar tensioning devices, and estimate automated system specifications such as motor requirements. A brief description of the new manufacturing process is also provided. Future work includes commercialization of the technology, automation of the manufacturing system, and further modeling work to predict fiber spreading behavior based on geometric factors.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140657830","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Arpan Patel, Samantha Webster, Jian Cao, K. Ehmann
Laser polishing (LP) provides a fast and efficient way of re-melting part surfaces manufactured by additive manufacturing to alter both their geometric as well as physical properties. Depending on the laser parameters, remelted surfaces with different properties are achieved, with a majority exhibiting lower surface roughness compared to the original surface. In this study, a high-power continuous fiber laser is used to polish Inconel 718 surfaces produced by depositing a single layer of clads on a steel substrate by the powder-blown directed energy deposition (DED) process. Polishing was performed under different sets of parameters, namely, laser power, beam diameter, feed rate or feed, hatch space, and the number of polishing passes. Their effects on the surface roughness profiles and the microstructural properties of the sample cross-section were analyzed after one and two polishing passes. Optical microscopic images of the sample's cross-sections show the presence of supersaturated γ phase particles, γ′ + γ″ precipitates, Laves phases, and δ phase needles. The combined effect of high-temperature gradients and lower solidification rates in certain regions within the cross-section result in undercooled regions and pseudo heat treatment of unmelted regions close to the undercooled regions. These results are corroborated by indenting the various regions of the IN718 sample cross-section with a pyramidal diamond indenter in the form of a grid, resulting in different micro-hardness values due to different densities of precipitate and phase-transformed δ particles.
{"title":"Multi-pass laser polishing of as-built DED surfaces","authors":"Arpan Patel, Samantha Webster, Jian Cao, K. Ehmann","doi":"10.1115/1.4065361","DOIUrl":"https://doi.org/10.1115/1.4065361","url":null,"abstract":"\u0000 Laser polishing (LP) provides a fast and efficient way of re-melting part surfaces manufactured by additive manufacturing to alter both their geometric as well as physical properties. Depending on the laser parameters, remelted surfaces with different properties are achieved, with a majority exhibiting lower surface roughness compared to the original surface. In this study, a high-power continuous fiber laser is used to polish Inconel 718 surfaces produced by depositing a single layer of clads on a steel substrate by the powder-blown directed energy deposition (DED) process. Polishing was performed under different sets of parameters, namely, laser power, beam diameter, feed rate or feed, hatch space, and the number of polishing passes. Their effects on the surface roughness profiles and the microstructural properties of the sample cross-section were analyzed after one and two polishing passes. Optical microscopic images of the sample's cross-sections show the presence of supersaturated γ phase particles, γ′ + γ″ precipitates, Laves phases, and δ phase needles. The combined effect of high-temperature gradients and lower solidification rates in certain regions within the cross-section result in undercooled regions and pseudo heat treatment of unmelted regions close to the undercooled regions. These results are corroborated by indenting the various regions of the IN718 sample cross-section with a pyramidal diamond indenter in the form of a grid, resulting in different micro-hardness values due to different densities of precipitate and phase-transformed δ particles.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140673706","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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