International Journal of Lightweight Materials and Manufacture最新文献_第4页

Investigation and optimization of machining parameters in Micro-WEDM of SMA to enhance performance SMA微细线切割加工参数的研究与优化，提高加工性能

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-03-07 DOI: 10.1016/j.ijlmm.2025.03.002

Rakesh R. Kolhapure , Duradundi S. Badkar

Ti–Ni Shape Memory Alloys (SMAs) are extensively used in biomedical applications due to their superior biocompatibility and mechanical properties over traditional biomaterial SS316L and Ti alloys. However, achieving high precision and surface integrity during machining remains a significant challenge. This study focuses on optimizing the Micro-Wire Electric Discharge Machining (μ-WEDM) parameters to enhance the machining efficiency and surface quality of Ti–Ni SMAs. An L27 orthogonal array (OA) and Grey Relational Analysis (GRA) were applied to optimize multiple machining responses, including Material Removal Rate (MRR), Surface Roughness (SR), Dimensional Deviation (DD), and Kerf Width (KW) by using Voltage (V), Capacitance (C), and Wire feed (WF) as process parameters. Analysis of Variance (ANOVA) was conducted to evaluate the contribution of each parameter. The results indicate that ‘C’ significantly influences MRR (78.40 %), DD (50.98 %), and KW (36.64 %), while ‘V’ has the highest impact on SR (57.62 %). The optimal parameter combination (105 V, 6 nF, 1 mm/min) improved machining efficiency by 2.79 % (GRG) increased from 0.6898 to 0.7091, minimized surface defects, and enhanced dimensional accuracy. Scanning Electron Microscope (SEM) analysis confirmed that optimized μ-WEDM parameters minimized surface defects, refined textures, and reduced micro-cracks, enhancing surface integrity also minimizing recast layer results in dimensional accuracy. Energy Dispersive Spectroscopy (EDS) analysis verified minimal contamination, ensuring biocompatibility, making μ-WEDM ideal for high-precision biomedical applications. Furthermore, the study emphasizes the environmental sustainability of μ-WEDM, highlighting its reduced material waste and lower energy consumption compared to traditional machining methods. By integrating robust statistical analysis and process control, the study offers new insights into achieving good surface quality and performance in medical field.

Ti - ni形状记忆合金（sma）由于其优于传统生物材料SS316L和钛合金的生物相容性和机械性能而广泛应用于生物医学领域。然而，在加工过程中实现高精度和表面完整性仍然是一个重大挑战。为了提高Ti-Ni sma的加工效率和表面质量，对微线切割加工参数进行了优化研究。以电压(V)、电容(C)和进给丝（WF）为工艺参数，采用L27正交阵列（OA）和灰色关联分析（GRA）对材料去除率（MRR）、表面粗糙度（SR）、尺寸偏差（DD）和切口宽度（KW）等多个加工响应进行优化。进行方差分析（ANOVA）来评估每个参数的贡献。结果表明，“C”显著影响MRR（78.40%）、DD（50.98%）和KW(36.64%)，而“V”对SR的影响最大（57.62%）。最佳参数组合（105 V, 6 nF, 1 mm/min）使加工效率提高2.79% (GRG)，从0.6898提高到0.7091，表面缺陷最小化，尺寸精度提高。扫描电镜（SEM）分析证实，优化后的μ-WEDM参数最大限度地减少了表面缺陷，改善了织构，减少了微裂纹，提高了表面完整性，最大限度地减少了重铸层，提高了尺寸精度。能量色散光谱（EDS）分析验证了最小的污染，确保了生物相容性，使μ-WEDM成为高精度生物医学应用的理想选择。此外，该研究强调μ-电火花线切割的环境可持续性，强调与传统加工方法相比，μ-电火花线切割减少了材料浪费和降低了能耗。通过整合稳健的统计分析和过程控制，该研究为医疗领域实现良好的表面质量和性能提供了新的见解。

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引用次数: 0

Evaluation of mechanical and thermal properties of UV-curable resin-SiC composites for enhanced performance in abrasive applications 紫外光固化树脂-碳化硅复合材料的机械和热性能评价，以提高磨料应用的性能

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-03-04 DOI: 10.1016/j.ijlmm.2025.02.007

Babak Houshmand, Seyed Mohsen Safavi, Mehdi Karevan

This research investigates the mechanical and thermal properties of a novel composite material designed for applications in the finishing industry, particularly in abrasive tools such as grinding wheels. The composite comprises a UV-curable ABS-like resin, silicon carbide (SiC) grains with an average particle size of 150 μm, and fumed silica utilized as an anti-settling agent. The choice of ABS-like resin is motivated by its elasticity, which enhances impact resistance while minimizing thermal effects during usage. Fabrication of this composite material was achieved through stereolithography-based 3D printing technology, allowing for precise control over material properties and geometrical configurations.

Standard test specimens were produced and subjected to a comprehensive series of evaluations, including tensile strength, compression, Charpy impact, hardness, Differential Scanning Calorimetry (DSC), Heat Deflection Temperature (HDT), and wear tests, following ASTM standards. The results from these tests were analyzed to gain insight into the performance characteristics and applicability of this novel composite in demanding environments.

To further explore the capabilities of the discussed composite, two grinding tool samples were designed and manufactured. A comparison of grinding performance between the T100 tool, a structured tool, and the Simple Tool, a non-structured tool has been discussed. The analysis focuses on their efficiency when grinding Aluminum T6 and MO40 steel, examining critical performance parameters such as cutting forces, surface roughness, tool wear, force-damping behavior, and the impact of the elastic ABS-like resin used in these tools. This study provides valuable information for the implementation of such composites in the finishing industry, highlighting their potential advantages in abrasive applications.

本研究调查了一种新型复合材料的机械和热性能，该材料设计用于精加工工业，特别是磨具，如砂轮。该复合材料包括可紫外光固化的abs类树脂、平均粒径为150 μm的碳化硅（SiC）颗粒和用作抗沉降剂的气相二氧化硅。abs类树脂的选择是由其弹性驱动的，它增强了抗冲击性，同时最大限度地减少了使用过程中的热效应。这种复合材料的制造是通过基于立体光刻的3D打印技术实现的，可以精确控制材料的性能和几何结构。按照ASTM标准制作了标准试样，并进行了一系列全面的评估，包括拉伸强度、压缩、夏比冲击、硬度、差示扫描量热法（DSC）、热偏转温度（HDT）和磨损测试。对这些测试结果进行了分析，以深入了解这种新型复合材料在苛刻环境中的性能特征和适用性。为了进一步探索所讨论的复合材料的性能，设计和制造了两个磨具样品。对结构化刀具T100和非结构化刀具Simple tool的磨削性能进行了比较。分析的重点是它们在磨削铝T6和MO40钢时的效率，检查关键性能参数，如切削力、表面粗糙度、刀具磨损、力阻尼行为，以及这些工具中使用的弹性abs类树脂的影响。本研究为这种复合材料在精加工工业中的应用提供了有价值的信息，突出了它们在磨料应用中的潜在优势。

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引用次数: 0

Sustainability-driven additive manufacturing: Implementation and content optimization of fine powder recycled glass in polylactic acid for material extrusion 3D printing 可持续发展驱动的增材制造：用于材料挤压3D打印的聚乳酸细粉再生玻璃的实现和含量优化

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-03-03 DOI: 10.1016/j.ijlmm.2025.02.008

Markos Petousis , Nikolaos Michailidis , Václav Kulas , Vassilis Papadakis , Mariza Spiridaki , Nikolaos Mountakis , Apostolos Argyros , John Valsamos , Nektarios K. Nasikas , Nectarios Vidakis

This work aimed to evaluate the capacity of recycled fine powder glass (RFPG) to reinforce the mechanical performance and characteristics of polylactic acid (PLA) for use in 3D printing (3DP) applications. Six composites with an RFPG filler quantity of 2.0 wt % −12.0 wt % (with a 2.0 step) were evaluated. The raw materials were turned into mixtures, which then fabricated respective filaments. The filaments were inspected and tested for their properties before being utilized to produce the specimens for testing with 3DP. The structures, morphologies, and mechanical properties of the specimens were examined by performing respective tests, scanning electron microscopy, and micro-computed tomography (μ-CT). Moreover, the samples were tested for their thermal properties through thermogravimetric and differential scanning calorimetry analyses, and for their rheological performance. Quality metrics were evaluated with μ-CT (porosity and dimensional accuracy). The findings indicated that RFPG as a filler reinforced the PLA matrix, in the case of 6.0 wt % (23.6 % and 28.7 % strength enhancement in the flexural and tensile tests respectively). The thermal properties were insignificantly changed with a small increase in the crystallization temperature, while the viscosity was significantly lowered with the increase of the powder content in the compounds. The quality metrics were enhanced as well, making this specific RFPG grade a promising filler for the PLA matrix in 3D printing.

这项工作旨在评估再生细粉玻璃（RFPG）的能力，以加强用于3D打印（3DP）应用的聚乳酸（PLA）的机械性能和特性。评估了六种RFPG填充量为2.0 wt % ~ 12.0 wt %（步长为2.0）的复合材料。原料被制成混合物，然后制成各自的长丝。细丝被检查和测试了他们的性能，然后被用来生产样品，用3d打印测试。通过扫描电子显微镜和微计算机断层扫描（μ-CT）对样品的结构、形态和力学性能进行了检测。此外，通过热重和差示扫描量热分析测试了样品的热性能，并测试了它们的流变性能。采用μ-CT（孔隙度和尺寸精度）评价质量指标。研究结果表明，RFPG作为填料增强PLA基体，在6.0 wt %的情况下（在弯曲和拉伸试验中分别提高23.6%和28.7%的强度）。随着结晶温度的升高，结晶物的热性能变化不大，而随着粉体含量的增加，结晶物的粘度明显降低。质量指标也得到了提高，使这种特殊的RFPG等级成为3D打印中PLA矩阵的有前途的填料。

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引用次数: 0

Machine learning in additive manufacturing: A comprehensive insight 增材制造中的机器学习：全面洞察

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-03-01 DOI: 10.1016/j.ijlmm.2024.10.002

Md Asif Equbal , Azhar Equbal , Zahid A. Khan , Irfan Anjum Badruddin

Additive manufacturing (AM) is a technological advancement gaining colossal popularity due to its advantages and simplified fabrication. AM facilitates the manufacturing of complex, light, and strong products from digitized designs. With recent advancements, AM can bring digital flexibility and improved efficiency to industrial operations. Despite the various advantages, there is continuous variation in the qualities of AM products, which remains the main challenge in the wide application of AM. The performance of printed parts is directly influenced by processing parameters, and adjusting the parameters in the AM process can be quite challenging. The barrier can be minimized by proper monitoring of the AM process and precise measurement of AM materials and components, which is difficult to achieve through analytical and numerical models. Current research demonstrates machine learning (ML) and its techniques as a novel way to reduce costs. It also helps achieve optimal process design and part quality using the fundamentals of the AM process. ML is a subcategory of artificial intelligence (AI) that enables systems to learn and improve from measured data and past experiences. The present paper is focused on presenting a broad understanding of the current applications of ML in AM and thus provides a solid background for practitioners and researchers to apply ML in AM. Very few earlier reviews were presented before, but their studies mostly focus on artificial neural network technology and other irrelevant papers. In addition, most papers were published in 2021 and 2022 and were not discussed in earlier reviews. This state-of-the-art review is based on the latest database collected from Web of Science (WoS), Publons, Scopus, and Google Scholar using machine learning and additive manufacturing as the keywords. Extensive information collected on the possible applications of ML in AM shows that ML can be effectively applied to improve AM part quality and process reliability.

增材制造（AM）是一项技术进步，由于其优势和简化的制造而获得巨大的普及。增材制造有助于从数字化设计中制造复杂、轻便和坚固的产品。随着最近的进步，增材制造可以为工业运营带来数字灵活性和更高的效率。尽管有各种各样的优势，但增材制造产品的质量不断变化，这仍然是增材制造广泛应用的主要挑战。打印件的性能直接受到加工参数的影响，在增材制造过程中调整参数是相当具有挑战性的。通过对增材制造过程的适当监控和对增材制造材料和部件的精确测量，可以最大限度地减少这种障碍，这是通过分析和数值模型难以实现的。目前的研究表明，机器学习（ML）及其技术是降低成本的一种新方法。它还有助于利用增材制造工艺的基本原理实现最佳工艺设计和零件质量。机器学习是人工智能（AI）的一个子类，它使系统能够从测量数据和过去的经验中学习和改进。本文的重点是对当前机器学习在增材制造中的应用进行广泛的理解，从而为从业者和研究人员在增材制造中应用机器学习提供坚实的背景。之前很少有早期的综述，但他们的研究主要集中在人工神经网络技术和其他不相关的论文。此外，大多数论文发表于2021年和2022年，未在早期综述中讨论。这篇最先进的综述基于从Web of Science （WoS）、Publons、Scopus和b谷歌Scholar收集的最新数据库，以机器学习和增材制造为关键词。收集了大量关于机器学习在增材制造中可能应用的信息，表明机器学习可以有效地应用于提高增材制造零件质量和工艺可靠性。

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引用次数: 0

Experimental performance evaluation of a lightweight additively manufactured hydrodynamic thrust bearing 增材制造轻量化流体动力推力轴承的实验性能评价

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-03-01 DOI: 10.1016/j.ijlmm.2024.10.003

Collier Fais , Isaiah Yasko , Muhammad Ali , Rick Walker , Joe Walker

In this paper, a lightweight additively manufactured (AM) fixed geometry hydrodynamic thrust bearing fabricated via laser powder bed fusion (LPBF) is experimentally compared to a traditionally manufactured cast aluminum alloy thrust bearing of similar design. The purpose of this study is to evaluate how weight-saving design features in the AM bearing affect active critical hydrodynamic performance parameters to better understand in-service viability. Under various static operating conditions, performance parameters such as hydrodynamic pressure distribution, minimum oil film thickness (MOFT), bearing temperature and increase in oil temperature are measured. Compared to the traditionally manufactured bearing, the AM bearing showed an average increase in minimum oil film thickness of 53 %, an average increase in trailing edge hydrodynamic pressure of 116 %, while exhibiting an average decrease in bearing temperature of 1 %. Experimental results are compared to numerical simulation showing reasonably good agreement.

本文采用激光粉末床熔合（LPBF）技术制备了一种轻型增材制造（AM）固定几何流体动力推力轴承，并与传统制造的类似设计的铸铝合金推力轴承进行了实验比较。本研究的目的是评估AM轴承的减重设计特征如何影响主动临界流体动力性能参数，以更好地了解在役可行性。在各种静态工况下，测量了动水压力分布、最小油膜厚度（MOFT）、轴承温度和油温升高等性能参数。与传统制造的轴承相比，增材制造轴承的最小油膜厚度平均增加53%，尾缘动水压力平均增加116%，轴承温度平均降低1%。实验结果与数值模拟结果吻合较好。

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引用次数: 0

Enhancement of the mechanical characteristics for Inconel 700 alloy using friction stir welding with a unique tool shape 采用独特的工具形状搅拌摩擦焊接，提高了Inconel 700合金的机械性能

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-02-12 DOI: 10.1016/j.ijlmm.2025.02.005

Ibrahim Sabry , Omar Awayssa , Abdel-Hamid I. Mourad , Majid Naseri , Ahmed Hewidy

For the first time, a systematic study of the influence of tool geometry on the friction stir welding (FSW) process of Inconel 700 through response surface methodology (RSM) for modeling purposes was investigated. The tool design implemented two distinct pin probe geometries: a threaded pin with three intermittent flat faces (D1) and a fully threaded cylindrical pin (D2). The present study primarily examines the effects of these varying pin geometries on FSW performance in Inconel 700 joints. Additionally, experimental analyses, i.e., Vickers hardness number (VHN), ultimate tensile strength (UTS), and surface roughness (SR), were conducted to evaluate key mechanical properties. The response surface methodology (RSM) was evaluated as a suitable approach for determining the weld properties, with mathematical models achieving confidence levels of 93 % and 98 % for the D1 and D2 tool configurations, respectively. Meanwhile, the D1 pin geometry produced superior mechanical properties, i.e., UTS from 630 to 662 MPa, VHN from 93 to 110 HV, and improved surface finish compared to the D2 configuration, highlighting the design's effectiveness in enhancing FSW joint quality.

本文首次采用响应面法（RSM）对Inconel 700搅拌摩擦焊接过程中刀具几何形状的影响进行了系统研究。该工具设计实现了两种不同的针探头几何形状：具有三个间歇平面的螺纹针（D1）和全螺纹圆柱形针（D2）。本研究主要考察了这些不同的销形对Inconel 700接头FSW性能的影响。此外，还进行了实验分析，即维氏硬度值（VHN）、极限抗拉强度（UTS）和表面粗糙度（SR），以评估关键力学性能。响应面法（RSM）被评价为确定焊缝性能的合适方法，D1和D2工具配置的数学模型分别达到93%和98%的置信度。与此同时，与D2结构相比，D1销形结构产生了卓越的机械性能，即UTS从630到662 MPa， VHN从93到110 HV，并且表面光洁度得到改善，突出了该设计在提高FSW连接质量方面的有效性。

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引用次数: 0

Hierarchical cubic lattice structures with bending- and stretching-dominated cellular designs for enhanced buckling resistance 具有弯曲和拉伸主导的细胞设计的分层立方晶格结构增强抗屈曲

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-02-10 DOI: 10.1016/j.ijlmm.2025.02.002

A. Viswanath , M. Khalil , M.K.A. Khan , W.J. Cantwell , K.A. Khan

Buckling is a common failure mode in low-density strut lattices, limiting their mechanical strength and stability. This work presents a novel methodology to design and manufacture lightweight, buckling-resistant strut-based lattice structures by reinforcing buckling-prone members with hierarchical lattice unit cells—either stretching- or bending-dominated—without changing the strut lattice's relative density. Four types of lattice unit cells were examined: plate, honeycomb, strut, and TPMS solids and sheets. These were tested on single-cell cubic lattice columns with square cross-sectional struts. The resulting hierarchical structures were additively manufactured and experimentally evaluated, demonstrating significantly enhanced buckling performance. Design for additive manufacturing principles were applied, and structures with stretching and bending-dominated unit cells achieved higher critical buckling loads, with the square honeycomb cell lattice showing the highest improvement at 179 % over the baseline. This approach broadens opportunities for enhancing low-density strut lattices and developing novel buckling-resistant designs.

屈曲是低密度结构中常见的破坏形式，限制了结构的机械强度和稳定性。这项工作提出了一种新的方法来设计和制造轻质的，抗屈曲的基于支柱的晶格结构，通过用分层晶格单元加强易屈曲的成员-拉伸或弯曲主导-而不改变支柱晶格的相对密度。四种类型的晶格单元细胞进行了检查：板，蜂窝，支柱和TPMS固体和片。这些都是在具有方形横截面支柱的单室立方格子柱上进行测试的。所得到的层次化结构经过增材制造和实验评估，显示出显著增强的屈曲性能。应用了增材制造原理的设计，拉伸和弯曲主导的单元格结构获得了更高的临界屈曲载荷，方形蜂窝单元格比基线提高了179%。这种方法拓宽了增强低密度支撑网格和开发新型抗屈曲设计的机会。

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引用次数: 0

Enhancing the mechanical properties of 3D-Printed polylactic acid through pellet additive manufacturing: A grey relational analysis based on entropy weights 通过颗粒增材制造提高3d打印聚乳酸的力学性能：基于熵权的灰色关联分析

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-02-07 DOI: 10.1016/j.ijlmm.2025.02.003

Radhika Mandala , B. Anjaneya Prasad , Suresh Akella

The most prevalent and extensively employed additive manufacturing (AM) approach method is fused deposition modeling (FDM), which uses filament as feedstock. Pellet additive manufacturing (PAM) is an emerging technique within the field of FDM that utilizes thermoplastic pellets as the feedstock considering their greater ease of production compared to filaments. The PAM technique enables the production of intricate components with high dimensional precision and cost efficiency by eliminating the need to transform pellets into filaments. The discreet choice of printing parameters greatly influences the performance of 3D-printed objects. This work underscores the significance of printing parameters on mechanical performance measures, tensile, flexure, and hardness characteristics by utilizing a multi-objective optimization technique. It is a combination of the Taguchi, analysis of variance (ANOVA), and entropy-based grey relational analysis (EGRA). A Taguchi L9 orthogonal array is employed, with infill pattern, raster angle, and layer height as the control variables, while tensile and flexural strengths, and hardness serve as the output responses. The findings demonstrated that the optimum outcomes were achieved for the gyroid infill pattern at 45° orientation and 0.25 mm layer height. Enforcing EGRA in multi-objective optimization has resulted in an improvement of 3.3 % in the grey relational grade when compared to the initial parameter configurations. Hence, EGRA proves to be an effective potential tool for the optimization process in PAM.

最普遍和广泛使用的增材制造（AM）方法是熔融沉积建模（FDM），它使用长丝作为原料。颗粒增材制造（PAM）是FDM领域的一项新兴技术，它利用热塑性颗粒作为原料，考虑到它们比长丝更容易生产。PAM技术通过消除将颗粒转化为长丝的需要，使复杂部件的生产具有高尺寸精度和成本效益。打印参数的谨慎选择极大地影响了3d打印对象的性能。这项工作强调了印刷参数对机械性能测量，拉伸，弯曲和硬度特性的重要性，利用多目标优化技术。它是田口法、方差分析（ANOVA）和基于熵的灰色关联分析（EGRA）的结合。采用田口L9正交阵列，以填充模式、栅格角度和层高为控制变量，拉伸、弯曲强度和硬度作为输出响应。结果表明，在45°方向和0.25 mm层高的旋转充填模式下，获得了最佳效果。与初始参数配置相比，在多目标优化中执行EGRA导致灰色关联等级提高3.3%。因此，EGRA被证明是PAM优化过程中一种有效的潜在工具。

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引用次数: 0

Bending-hydraulic forming stainless steel thin-walled tube fittings wall thickness distribution law research 弯曲-液压成形不锈钢薄壁管件壁厚分布规律研究

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-02-06 DOI: 10.1016/j.ijlmm.2025.02.004

Xinlong Zhang, Jiang Xiao, Xiaodong Xie, Zhaosong Jiang, Xueyan Liu

A study was conducted to examine the distribution of wall thickness in stainless steel thin-walled tube fittings during the forming process. The research included simulation and experimental analyses of the bending and hydroforming processes of these fittings used in a passenger car. The goal was to analyze how process parameters affect the distribution of wall thickness. Auto Form software was utilized to simulate the bending process and investigate the impact of relative bending radius (Relative bending radius for the tube fittings bending neutral layer of the ratio of the radius and diameter of the tube) on the wall thickness distribution. Subsequently, hydroforming simulations were performed under varying internal pressure loading conditions. The findings revealed that as the relative bending radius increased, both the maximum thinning rate and maximum thickening rate of the tube fittings gradually decreased. Based on the simulation outcomes, the optimal bending process parameters were determined to be a 62 mm initial tube diameter and a 95 mm bending radius. Through finite element simulations of hydroforming, internal pressures of 30 MPa, 40 MPa, and 50 MPa were compared, with 40 MPa identified as the optimal pressure for forming. The thin-walled tube fittings were then manufactured based on the optimal parameters obtained from the simulation, which were validated through experimentation. The experimental results closely matched the simulation results, with a maximum error margin of 2.27 %. The final formed parts met all requirements without any failures.

对不锈钢薄壁管件在成形过程中的壁厚分布进行了研究。对某客车用接头的弯曲和液压成形过程进行了仿真和实验分析。目的是分析工艺参数对壁厚分布的影响。利用Auto Form软件对弯曲过程进行模拟，研究相对弯曲半径（管件弯曲中性层的相对弯曲半径与管径之比）对壁厚分布的影响。随后，在不同的内压加载条件下进行了液压成形模拟。结果表明：随着相对弯曲半径的增大，管件的最大减薄速率和最大增厚速率均逐渐减小；根据仿真结果，确定了最优弯曲工艺参数为初始管径为62 mm，弯曲半径为95 mm。通过液压成形有限元模拟，对比了30 MPa、40 MPa和50 MPa的内压力，确定了40 MPa为最优成形压力。根据仿真得到的最优参数进行了薄壁管件的加工，并通过实验验证了优化参数的正确性。实验结果与仿真结果吻合较好，最大误差为2.27%。最终成形的零件符合各项要求，无任何故障。

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引用次数: 0

Nondestructive test for quality control in laboratory-scale fabrication of laminated composites using programmable portable ultrasonic 实验室规模层压复合材料制造质量控制的可编程便携式超声无损检测

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-02-05 DOI: 10.1016/j.ijlmm.2025.02.006

Yusuf Giri Wijaya , Suprijanto , Damar Rastri Adhika , Rhakamerta Hijazi , Abian Nurrohmad

Laminated composites are the most frequently used component materials in manufacturing unmanned aerial vehicles (UAVs) in research centers or start-up industries. On a laboratory scale, laminated composites are fabricated by relying on technicians' skills due to the involvement of manual processes. Nondestructive testing (NDT) is needed to guarantee the structural integrity of the final product of laminated composites. The work proposes a programmable portable ultrasonic for nondestructive testing (NDT) to detect a potential defect due to foreign object contamination of fabrication layers of laminate composite. The proposed programmable NDT system is built using open-board devices; therefore, it could be developed cost-effectively compared to a commercial NDT system. The proposed NDT can measure and analyze a pattern of A-scan signal as a function of foreign object contamination material. Based on a C-scan image, the proposed NDT system could also be programmed to detect the size area of potential defects due to foreign object contamination. Two types of specimens, carbon fiber-reinforced polymer (CFRP) and glass fiber-reinforced polymer (GFRP), were tested to evaluate the performance of the developed NDT system. Testing aims to identify artificial defects intentionally placed within these specimens. The proposed portable ultrasonic NDT effectively detects CFRP and GFRP defects on A-mode and C-scan images. Therefore, the proposed portable ultrasonic NDT is an affordable system that can be developed in a laboratory workshop for quality control in laboratory-scale fabrication of laminated composites.

叠层复合材料是研究中心或初创企业制造无人机（uav）最常用的部件材料。在实验室规模上，层压复合材料的制造依赖于技术人员的技能，因为涉及手工过程。为了保证层合复合材料最终产品的结构完整性，需要进行无损检测。提出了一种可编程便携式超声无损检测（NDT），用于检测由于异物污染层合复合材料制造层的潜在缺陷。所提出的可编程无损检测系统采用开板器件构建；因此，与商业无损检测系统相比，它的开发成本更低。所提出的无损检测可以测量和分析a扫描信号的模式，作为异物污染材料的函数。基于c扫描图像，提出的无损检测系统也可以被编程来检测由于异物污染的潜在缺陷的大小区域。对碳纤维增强聚合物（CFRP）和玻璃纤维增强聚合物（GFRP）两种试样进行了测试，以评估所开发的无损检测系统的性能。测试的目的是识别故意放置在这些样本中的人为缺陷。本文提出的便携式超声无损检测方法可在a型和c型扫描图像上有效检测CFRP和GFRP缺陷。因此，所提出的便携式超声无损检测是一种负担得起的系统，可以在实验室车间开发，用于实验室规模的层压复合材料制造的质量控制。

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