This work aims to study the cutting behavior of biocomposites under different controlled hygrothermal conditions. This investigation choice is motivated by the fact that natural plant fibers such as flax are characterized by their hydrophilicity which makes them able to absorb water from a humid environment. This absorption ability is intensified when increasing the conditioning temperature. The moisture diffusion process affects considerably the mechanical properties of the resulting composite, which causes many issues during the machining operations. In this paper, moisture diffusion, chip form, cutting and thrust forces, and the microscopic state of the machined surfaces are considered to explore the cutting behavior of biocomposites in the function of the hygrothermal conditioning time. Results reveal that moisture content in the biocomposite is significantly influenced by the conditioning temperature and the fiber orientation. The evolution of the moisture content and the increase of the fiber orientation affect both the chip morphology in terms of curling as well as the tool/chip interaction in terms of friction. The cutting behavior of flax fibers depending on hygrothermal conditioning time is then investigated using microscopic observations of the machined surfaces in addition to analytical modeling. An analysis of variance is used finally to quantify the observed results.
{"title":"Effect of hygrothermal conditioning on the machining behavior of biocomposites","authors":"Faissal Chegdani, M. El Mansori","doi":"10.1115/1.4064690","DOIUrl":"https://doi.org/10.1115/1.4064690","url":null,"abstract":"\u0000 This work aims to study the cutting behavior of biocomposites under different controlled hygrothermal conditions. This investigation choice is motivated by the fact that natural plant fibers such as flax are characterized by their hydrophilicity which makes them able to absorb water from a humid environment. This absorption ability is intensified when increasing the conditioning temperature. The moisture diffusion process affects considerably the mechanical properties of the resulting composite, which causes many issues during the machining operations. In this paper, moisture diffusion, chip form, cutting and thrust forces, and the microscopic state of the machined surfaces are considered to explore the cutting behavior of biocomposites in the function of the hygrothermal conditioning time. Results reveal that moisture content in the biocomposite is significantly influenced by the conditioning temperature and the fiber orientation. The evolution of the moisture content and the increase of the fiber orientation affect both the chip morphology in terms of curling as well as the tool/chip interaction in terms of friction. The cutting behavior of flax fibers depending on hygrothermal conditioning time is then investigated using microscopic observations of the machined surfaces in addition to analytical modeling. An analysis of variance is used finally to quantify the observed results.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139854419","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}
Cryogenic medium pressure forming has been developed to form the complex-shaped tubular components, in which the need shape and tube diameter directly determine the complex evolution of biaxial stress in bulging process. The superposition of biaxial stress and cryogenic temperature complicates the deformation behaviors, especially for the final fracture and bulging limit, which determine forming quality of components. Therefore, the effects of tube geometry on failure orientation and fracture strain of Al–Mg–Si alloy tubes under cryogenic biaxial stress was elucidated, by utilizing cryogenic free bulging with different length–diameter ratios. The failure orientations and corresponding damage modes under different bulging geometric conditions were revealed. The influence mechanism of tube geometry and temperature on the failure mode was analyzed theoretically. A fracture model was established to predict the fracture strain in cryogenic bulging. The failure mode changes from circumferential cracking to axial cracking with the decreasing length–diameter ratio, owing to the stress sequence reversal induced by the significant nonlinearity of stress path under small length–diameter ratio. And the failure mode can inverse under a larger length–diameter ratio of 1.0 at −196 °C because of the enhanced nonlinearity, which is promoted by the improved plasticity at cryogenic temperature. The established model based on the more accurate assessment of hardening ability during deformation can accurately predict the fracture strain with an average deviation of 10.6% at different temperatures. The study can guide deformation analysis and failure prediction in cryogenic forming of aluminum alloy tubular parts.
{"title":"Cryogenic failure behaviors of Al-Mg-Si alloy tubes in bulging process","authors":"Xiaobo Fan, Xugang Wang, X. Chen, Shijian Yuan","doi":"10.1115/1.4064691","DOIUrl":"https://doi.org/10.1115/1.4064691","url":null,"abstract":"\u0000 Cryogenic medium pressure forming has been developed to form the complex-shaped tubular components, in which the need shape and tube diameter directly determine the complex evolution of biaxial stress in bulging process. The superposition of biaxial stress and cryogenic temperature complicates the deformation behaviors, especially for the final fracture and bulging limit, which determine forming quality of components. Therefore, the effects of tube geometry on failure orientation and fracture strain of Al–Mg–Si alloy tubes under cryogenic biaxial stress was elucidated, by utilizing cryogenic free bulging with different length–diameter ratios. The failure orientations and corresponding damage modes under different bulging geometric conditions were revealed. The influence mechanism of tube geometry and temperature on the failure mode was analyzed theoretically. A fracture model was established to predict the fracture strain in cryogenic bulging. The failure mode changes from circumferential cracking to axial cracking with the decreasing length–diameter ratio, owing to the stress sequence reversal induced by the significant nonlinearity of stress path under small length–diameter ratio. And the failure mode can inverse under a larger length–diameter ratio of 1.0 at −196 °C because of the enhanced nonlinearity, which is promoted by the improved plasticity at cryogenic temperature. The established model based on the more accurate assessment of hardening ability during deformation can accurately predict the fracture strain with an average deviation of 10.6% at different temperatures. The study can guide deformation analysis and failure prediction in cryogenic forming of aluminum alloy tubular parts.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139855625","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}
The effects of a hybrid process that combines ultrasonic cavitation and electrochemical polishing on the electrochemical behavior and the resulting surface characteristics of additively manufactured 316L stainless steel were investigated. In-situ potentiodynamic scans and electrochemical impedance spectroscopy (EIS) were conducted to gain fundamental understanding of the effect of ultrasonic cavitation on the electrochemical processes involved, considering the influence of electrolyte temperature at 60 and 70°C. The potentiodynamic scans revealed that increasing the ultrasonic excitation amplitude from 20 to 80 µm at 20 µm intervals and temperature from 60 to 70°C led to reduced polishing resistance, elevated passivation current density at equivalent applied potentials, thus leading to an increased polishing rate. These findings are attributed to intensified cavitation near the material surface, which promoted anodic dissolution reactions and accelerated the polishing rate. In-situ EIS measurements provided valuable information on the charge transfer resistance and double-layer capacitance and their influence on the hybrid process. Specifically, higher ultrasonic amplitudes and elevated temperatures contributed to enhanced electrical double-layer formation and ion adsorption, resulting in a faster rate of polishing, indicating the efficacy of the hybrid process. These findings enhance our understanding of the complex interactions between ultrasonic cavitation and electrochemical dissolution processes that occur during ultrasonic cavitation-assisted electrochemical polishing. The research provides valuable insights for optimizing the process and its potential application in post-processing of metal additive manufactured parts.
{"title":"In-situ Analysis of the Effect of Ultrasonic Cavitation on Electrochemical Polishing of Additively Manufactured Metal Surfaces","authors":"Ji Ho Jeon, Sung-Hoon Ahn, S. Melkote","doi":"10.1115/1.4064692","DOIUrl":"https://doi.org/10.1115/1.4064692","url":null,"abstract":"\u0000 The effects of a hybrid process that combines ultrasonic cavitation and electrochemical polishing on the electrochemical behavior and the resulting surface characteristics of additively manufactured 316L stainless steel were investigated. In-situ potentiodynamic scans and electrochemical impedance spectroscopy (EIS) were conducted to gain fundamental understanding of the effect of ultrasonic cavitation on the electrochemical processes involved, considering the influence of electrolyte temperature at 60 and 70°C. The potentiodynamic scans revealed that increasing the ultrasonic excitation amplitude from 20 to 80 µm at 20 µm intervals and temperature from 60 to 70°C led to reduced polishing resistance, elevated passivation current density at equivalent applied potentials, thus leading to an increased polishing rate. These findings are attributed to intensified cavitation near the material surface, which promoted anodic dissolution reactions and accelerated the polishing rate. In-situ EIS measurements provided valuable information on the charge transfer resistance and double-layer capacitance and their influence on the hybrid process. Specifically, higher ultrasonic amplitudes and elevated temperatures contributed to enhanced electrical double-layer formation and ion adsorption, resulting in a faster rate of polishing, indicating the efficacy of the hybrid process. These findings enhance our understanding of the complex interactions between ultrasonic cavitation and electrochemical dissolution processes that occur during ultrasonic cavitation-assisted electrochemical polishing. The research provides valuable insights for optimizing the process and its potential application in post-processing of metal additive manufactured parts.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139795146","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}
This work aims to study the cutting behavior of biocomposites under different controlled hygrothermal conditions. This investigation choice is motivated by the fact that natural plant fibers such as flax are characterized by their hydrophilicity which makes them able to absorb water from a humid environment. This absorption ability is intensified when increasing the conditioning temperature. The moisture diffusion process affects considerably the mechanical properties of the resulting composite, which causes many issues during the machining operations. In this paper, moisture diffusion, chip form, cutting and thrust forces, and the microscopic state of the machined surfaces are considered to explore the cutting behavior of biocomposites in the function of the hygrothermal conditioning time. Results reveal that moisture content in the biocomposite is significantly influenced by the conditioning temperature and the fiber orientation. The evolution of the moisture content and the increase of the fiber orientation affect both the chip morphology in terms of curling as well as the tool/chip interaction in terms of friction. The cutting behavior of flax fibers depending on hygrothermal conditioning time is then investigated using microscopic observations of the machined surfaces in addition to analytical modeling. An analysis of variance is used finally to quantify the observed results.
{"title":"Effect of hygrothermal conditioning on the machining behavior of biocomposites","authors":"Faissal Chegdani, M. El Mansori","doi":"10.1115/1.4064690","DOIUrl":"https://doi.org/10.1115/1.4064690","url":null,"abstract":"\u0000 This work aims to study the cutting behavior of biocomposites under different controlled hygrothermal conditions. This investigation choice is motivated by the fact that natural plant fibers such as flax are characterized by their hydrophilicity which makes them able to absorb water from a humid environment. This absorption ability is intensified when increasing the conditioning temperature. The moisture diffusion process affects considerably the mechanical properties of the resulting composite, which causes many issues during the machining operations. In this paper, moisture diffusion, chip form, cutting and thrust forces, and the microscopic state of the machined surfaces are considered to explore the cutting behavior of biocomposites in the function of the hygrothermal conditioning time. Results reveal that moisture content in the biocomposite is significantly influenced by the conditioning temperature and the fiber orientation. The evolution of the moisture content and the increase of the fiber orientation affect both the chip morphology in terms of curling as well as the tool/chip interaction in terms of friction. The cutting behavior of flax fibers depending on hygrothermal conditioning time is then investigated using microscopic observations of the machined surfaces in addition to analytical modeling. An analysis of variance is used finally to quantify the observed results.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139794474","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}
Cryogenic medium pressure forming has been developed to form the complex-shaped tubular components, in which the need shape and tube diameter directly determine the complex evolution of biaxial stress in bulging process. The superposition of biaxial stress and cryogenic temperature complicates the deformation behaviors, especially for the final fracture and bulging limit, which determine forming quality of components. Therefore, the effects of tube geometry on failure orientation and fracture strain of Al–Mg–Si alloy tubes under cryogenic biaxial stress was elucidated, by utilizing cryogenic free bulging with different length–diameter ratios. The failure orientations and corresponding damage modes under different bulging geometric conditions were revealed. The influence mechanism of tube geometry and temperature on the failure mode was analyzed theoretically. A fracture model was established to predict the fracture strain in cryogenic bulging. The failure mode changes from circumferential cracking to axial cracking with the decreasing length–diameter ratio, owing to the stress sequence reversal induced by the significant nonlinearity of stress path under small length–diameter ratio. And the failure mode can inverse under a larger length–diameter ratio of 1.0 at −196 °C because of the enhanced nonlinearity, which is promoted by the improved plasticity at cryogenic temperature. The established model based on the more accurate assessment of hardening ability during deformation can accurately predict the fracture strain with an average deviation of 10.6% at different temperatures. The study can guide deformation analysis and failure prediction in cryogenic forming of aluminum alloy tubular parts.
低温中压成形已被开发用于成形形状复杂的管状部件，其中所需的形状和管径直接决定了鼓胀过程中双轴应力的复杂演变。双轴应力和低温温度的叠加使变形行为变得复杂，尤其是最终断裂和鼓包极限，这决定了部件的成型质量。因此，通过利用不同长径比的低温自由鼓胀，阐明了管材几何形状对低温双轴应力下铝镁硅合金管的破坏方向和断裂应变的影响。揭示了不同鼓胀几何条件下的破坏方向和相应的破坏模式。从理论上分析了管材几何形状和温度对破坏模式的影响机制。建立了预测低温鼓包断裂应变的断裂模型。随着长径比的减小，失效模式由周向开裂转变为轴向开裂，这是由于在小长径比条件下，应力路径的显著非线性引起了应力序列逆转。而在 -196 °C 时，由于低温塑性的改善，非线性增强，在较大的长径比（1.0）条件下，失效模式可以逆转。所建立的模型基于对变形过程中硬化能力的更精确评估，可准确预测不同温度下的断裂应变，平均偏差为 10.6%。该研究可为铝合金管状零件低温成形的变形分析和失效预测提供指导。
{"title":"Cryogenic failure behaviors of Al-Mg-Si alloy tubes in bulging process","authors":"Xiaobo Fan, Xugang Wang, X. Chen, Shijian Yuan","doi":"10.1115/1.4064691","DOIUrl":"https://doi.org/10.1115/1.4064691","url":null,"abstract":"\u0000 Cryogenic medium pressure forming has been developed to form the complex-shaped tubular components, in which the need shape and tube diameter directly determine the complex evolution of biaxial stress in bulging process. The superposition of biaxial stress and cryogenic temperature complicates the deformation behaviors, especially for the final fracture and bulging limit, which determine forming quality of components. Therefore, the effects of tube geometry on failure orientation and fracture strain of Al–Mg–Si alloy tubes under cryogenic biaxial stress was elucidated, by utilizing cryogenic free bulging with different length–diameter ratios. The failure orientations and corresponding damage modes under different bulging geometric conditions were revealed. The influence mechanism of tube geometry and temperature on the failure mode was analyzed theoretically. A fracture model was established to predict the fracture strain in cryogenic bulging. The failure mode changes from circumferential cracking to axial cracking with the decreasing length–diameter ratio, owing to the stress sequence reversal induced by the significant nonlinearity of stress path under small length–diameter ratio. And the failure mode can inverse under a larger length–diameter ratio of 1.0 at −196 °C because of the enhanced nonlinearity, which is promoted by the improved plasticity at cryogenic temperature. The established model based on the more accurate assessment of hardening ability during deformation can accurately predict the fracture strain with an average deviation of 10.6% at different temperatures. The study can guide deformation analysis and failure prediction in cryogenic forming of aluminum alloy tubular parts.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139795545","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}
The effects of a hybrid process that combines ultrasonic cavitation and electrochemical polishing on the electrochemical behavior and the resulting surface characteristics of additively manufactured 316L stainless steel were investigated. In-situ potentiodynamic scans and electrochemical impedance spectroscopy (EIS) were conducted to gain fundamental understanding of the effect of ultrasonic cavitation on the electrochemical processes involved, considering the influence of electrolyte temperature at 60 and 70°C. The potentiodynamic scans revealed that increasing the ultrasonic excitation amplitude from 20 to 80 µm at 20 µm intervals and temperature from 60 to 70°C led to reduced polishing resistance, elevated passivation current density at equivalent applied potentials, thus leading to an increased polishing rate. These findings are attributed to intensified cavitation near the material surface, which promoted anodic dissolution reactions and accelerated the polishing rate. In-situ EIS measurements provided valuable information on the charge transfer resistance and double-layer capacitance and their influence on the hybrid process. Specifically, higher ultrasonic amplitudes and elevated temperatures contributed to enhanced electrical double-layer formation and ion adsorption, resulting in a faster rate of polishing, indicating the efficacy of the hybrid process. These findings enhance our understanding of the complex interactions between ultrasonic cavitation and electrochemical dissolution processes that occur during ultrasonic cavitation-assisted electrochemical polishing. The research provides valuable insights for optimizing the process and its potential application in post-processing of metal additive manufactured parts.
{"title":"In-situ Analysis of the Effect of Ultrasonic Cavitation on Electrochemical Polishing of Additively Manufactured Metal Surfaces","authors":"Ji Ho Jeon, Sung-Hoon Ahn, S. Melkote","doi":"10.1115/1.4064692","DOIUrl":"https://doi.org/10.1115/1.4064692","url":null,"abstract":"\u0000 The effects of a hybrid process that combines ultrasonic cavitation and electrochemical polishing on the electrochemical behavior and the resulting surface characteristics of additively manufactured 316L stainless steel were investigated. In-situ potentiodynamic scans and electrochemical impedance spectroscopy (EIS) were conducted to gain fundamental understanding of the effect of ultrasonic cavitation on the electrochemical processes involved, considering the influence of electrolyte temperature at 60 and 70°C. The potentiodynamic scans revealed that increasing the ultrasonic excitation amplitude from 20 to 80 µm at 20 µm intervals and temperature from 60 to 70°C led to reduced polishing resistance, elevated passivation current density at equivalent applied potentials, thus leading to an increased polishing rate. These findings are attributed to intensified cavitation near the material surface, which promoted anodic dissolution reactions and accelerated the polishing rate. In-situ EIS measurements provided valuable information on the charge transfer resistance and double-layer capacitance and their influence on the hybrid process. Specifically, higher ultrasonic amplitudes and elevated temperatures contributed to enhanced electrical double-layer formation and ion adsorption, resulting in a faster rate of polishing, indicating the efficacy of the hybrid process. These findings enhance our understanding of the complex interactions between ultrasonic cavitation and electrochemical dissolution processes that occur during ultrasonic cavitation-assisted electrochemical polishing. The research provides valuable insights for optimizing the process and its potential application in post-processing of metal additive manufactured parts.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139855206","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}
This paper introduces a novel micro-elastic composite grinding pad for material removal. The study also developed a new grinding wear formula grounded in microcontact mechanics, which is crucial in examining the evolution of interface characteristics under optimal parameter combinations. The results showed that the MRR, reduction of roughness height (σ), and peak curvature radius (ρ) increase were the highest in the initial stage, followed by a slight increase in the real contact area in the second stage. This research suggests that abrasive particles primarily detach from the elastic pad in the second stage. The plasticity index (ψ) decreases during grinding, which suggests a transition from an elastic-plastic mixed contact interface to a predominantly elastic contact interface. This shift in the interface mechanics explains the gradual reduction in wear at the grinding interface. Both the plasticity index and the MRR are consistent throughout the grinding process. However, the plasticity index is a more effective index of interface wear than the conventional H/E ratio because it considers the surface roughness's shape and size, which is essential in mild grinding operations. The findings of this study can be used to improve the design and performance of micro-elastic composite grinding pads and to optimize the grinding process for improved efficiency and sustainability.
{"title":"An Investigation into the Grinding Characteristics and Wear Evolution of Micro-Elastic Composite Grinding Pads","authors":"Feng-Che Tsai","doi":"10.1115/1.4064627","DOIUrl":"https://doi.org/10.1115/1.4064627","url":null,"abstract":"\u0000 This paper introduces a novel micro-elastic composite grinding pad for material removal. The study also developed a new grinding wear formula grounded in microcontact mechanics, which is crucial in examining the evolution of interface characteristics under optimal parameter combinations. The results showed that the MRR, reduction of roughness height (σ), and peak curvature radius (ρ) increase were the highest in the initial stage, followed by a slight increase in the real contact area in the second stage. This research suggests that abrasive particles primarily detach from the elastic pad in the second stage. The plasticity index (ψ) decreases during grinding, which suggests a transition from an elastic-plastic mixed contact interface to a predominantly elastic contact interface. This shift in the interface mechanics explains the gradual reduction in wear at the grinding interface. Both the plasticity index and the MRR are consistent throughout the grinding process. However, the plasticity index is a more effective index of interface wear than the conventional H/E ratio because it considers the surface roughness's shape and size, which is essential in mild grinding operations. The findings of this study can be used to improve the design and performance of micro-elastic composite grinding pads and to optimize the grinding process for improved efficiency and sustainability.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140478761","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}
The emerging field of direct recycling for spent Li-ion batteries offers significant advantages, such as reduced energy expenses and minimized secondary pollution, when compared to traditional pyrometallurgical and hydrometallurgical methods. This is due to its direct utilization of the spent cathode as a raw material. However, efficient harvesting of spent cathode particles remains a challenge. To address this, this technical brief is the first to incorporate Resonant Acoustic Vibration Technology (RAV) as an efficient method for stripping cathode powders from spent Li-ion batteries. Our findings indicate that RAV-based techniques can achieve stripping efficiencies as high as 92%. A comparative analysis with conventional stripping methods, such as magnetic stirring, sonication, and curling-uncurling, reveals that RAV coupled with heat treatment provides unparalleled scalability and efficiency, eliminating the requirement for post-processing. Furthermore, the resulting cathode powders retain their original polycrystalline particle structures, with no impurities like carbon black or small aluminum fragments detected. These findings highlight the promise of RAV technology for large-scale recovery of electrode powders and its potential role in the direct recycling of spent Li-ion batteries.
{"title":"Resonant Acoustic Vibration-Assisted Cathode Stripping for Efficient Recycling of Spent Li-ion Batteries","authors":"Yaohong Xiao, Jinrong Su, Lei Chen","doi":"10.1115/1.4064629","DOIUrl":"https://doi.org/10.1115/1.4064629","url":null,"abstract":"\u0000 The emerging field of direct recycling for spent Li-ion batteries offers significant advantages, such as reduced energy expenses and minimized secondary pollution, when compared to traditional pyrometallurgical and hydrometallurgical methods. This is due to its direct utilization of the spent cathode as a raw material. However, efficient harvesting of spent cathode particles remains a challenge. To address this, this technical brief is the first to incorporate Resonant Acoustic Vibration Technology (RAV) as an efficient method for stripping cathode powders from spent Li-ion batteries. Our findings indicate that RAV-based techniques can achieve stripping efficiencies as high as 92%. A comparative analysis with conventional stripping methods, such as magnetic stirring, sonication, and curling-uncurling, reveals that RAV coupled with heat treatment provides unparalleled scalability and efficiency, eliminating the requirement for post-processing. Furthermore, the resulting cathode powders retain their original polycrystalline particle structures, with no impurities like carbon black or small aluminum fragments detected. These findings highlight the promise of RAV technology for large-scale recovery of electrode powders and its potential role in the direct recycling of spent Li-ion batteries.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140478174","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}
Henry Davis, James Harkness, Isa M. Kohls, Brian D Jensen, R. Vanfleet, Nathan B Crane, Robert Davis
High-temperature microfluidic devices (such as gas chromatography microcolumns) have traditionally been fabricated using photolithography, etching, and wafer bonding which allow for precise microscale features but lack the ability to form complex 3D designs. Metal additive manufacturing could enable higher complexity microfluidic designs if reliable methods for fabrication are developed, but forming small negative features is challenging—especially in powder-based processes. In this paper, the formation of sealed metal microchannels was demonstrated using stainless-steel binder jetting with bronze infiltration. To create small negative features, bronze infiltrant must fill the porous part produced by binder jetting without filling the negative features. This was achieved through sacrificial powder infiltration (SPI), wherein sacrificial powder reservoirs (pore size ∼60 μm) are used to control infiltrant pressure. With this pressure control, the infiltrant selectively filled the small pores between particles in the printed part (pore size ∼3 μm) while leaving printed microchannels (700 μm, 930 μm) empty. To develop the SPI method, a pore-filling study was performed in this stainless-steel/bronze system with 370 μm, 650 μm, and 930 μm microchannel segments. This study enabled SPI process design on these length scales by determining variations in pore filling across a sample and preferential filling between different-sized pores.
{"title":"Sacrificial Powder Pressure Control for Infiltration of Microscale Binder Jet Printed Metal Parts","authors":"Henry Davis, James Harkness, Isa M. Kohls, Brian D Jensen, R. Vanfleet, Nathan B Crane, Robert Davis","doi":"10.1115/1.4064628","DOIUrl":"https://doi.org/10.1115/1.4064628","url":null,"abstract":"\u0000 High-temperature microfluidic devices (such as gas chromatography microcolumns) have traditionally been fabricated using photolithography, etching, and wafer bonding which allow for precise microscale features but lack the ability to form complex 3D designs. Metal additive manufacturing could enable higher complexity microfluidic designs if reliable methods for fabrication are developed, but forming small negative features is challenging—especially in powder-based processes. In this paper, the formation of sealed metal microchannels was demonstrated using stainless-steel binder jetting with bronze infiltration. To create small negative features, bronze infiltrant must fill the porous part produced by binder jetting without filling the negative features. This was achieved through sacrificial powder infiltration (SPI), wherein sacrificial powder reservoirs (pore size ∼60 μm) are used to control infiltrant pressure. With this pressure control, the infiltrant selectively filled the small pores between particles in the printed part (pore size ∼3 μm) while leaving printed microchannels (700 μm, 930 μm) empty. To develop the SPI method, a pore-filling study was performed in this stainless-steel/bronze system with 370 μm, 650 μm, and 930 μm microchannel segments. This study enabled SPI process design on these length scales by determining variations in pore filling across a sample and preferential filling between different-sized pores.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140476706","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}
With the emergence of the Industrial Internet of Things(IIoT) and Industry 4.0, industrial automation has grown as an important vertical in recent years. Smart manufacturing techniques are now becoming essential to keeping up with the global industrial competition. Decreasing the machine's downtime and increasing tool life are crucial factors in reducing machining process costs. Therefore, introducing complete process automation utilizing an intelligent automation system can enhance the throughput of manufacturing processes. To achieve this, intelligent manufacturing systems can be designed to recognize materials they interact with and autonomously decide what actions to take whenever needed. This paper aims to present a generalized approach for fully automated machining processes to develop an intelligent manufacturing system. As an objective to accomplish this, the presence of workpiece material is automatically detected and identified in the proposed system using a CNN-based machine learning algorithm. Further, the CNC lathe's machining toolpath is automatically generated based on workpiece images for a surface finishing operation. Machining process parameters (spindle speed and feed rate) are also autonomously controlled, thus enabling full machining process automation. The implemented system introduces cognitive abilities into a machining system, creating an intelligent manufacturing ecosystem. The improvised system is capable of identifying various materials and generating toolpaths based on the type of workpieces. The accuracy and robustness of the system are also validated with different experimental setups. The presented results demonstrate that the proposed approach can be applied in manufacturing systems without the need for significant modification.
{"title":"Machining Process Automation in CNC Turning using Robot Assisted Imaging and CNN based Machine Learning","authors":"Chayan Maiti, Deep Patel, Sreekumar Muthuswamy","doi":"10.1115/1.4064626","DOIUrl":"https://doi.org/10.1115/1.4064626","url":null,"abstract":"\u0000 With the emergence of the Industrial Internet of Things(IIoT) and Industry 4.0, industrial automation has grown as an important vertical in recent years. Smart manufacturing techniques are now becoming essential to keeping up with the global industrial competition. Decreasing the machine's downtime and increasing tool life are crucial factors in reducing machining process costs. Therefore, introducing complete process automation utilizing an intelligent automation system can enhance the throughput of manufacturing processes. To achieve this, intelligent manufacturing systems can be designed to recognize materials they interact with and autonomously decide what actions to take whenever needed. This paper aims to present a generalized approach for fully automated machining processes to develop an intelligent manufacturing system. As an objective to accomplish this, the presence of workpiece material is automatically detected and identified in the proposed system using a CNN-based machine learning algorithm. Further, the CNC lathe's machining toolpath is automatically generated based on workpiece images for a surface finishing operation. Machining process parameters (spindle speed and feed rate) are also autonomously controlled, thus enabling full machining process automation. The implemented system introduces cognitive abilities into a machining system, creating an intelligent manufacturing ecosystem. The improvised system is capable of identifying various materials and generating toolpaths based on the type of workpieces. The accuracy and robustness of the system are also validated with different experimental setups. The presented results demonstrate that the proposed approach can be applied in manufacturing systems without the need for significant modification.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140474036","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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