Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.04.043
Cheng-Hao Chou, Chenhui Shao, Chinedum E. Okwudire (2)
Cutting operations often involve machining parts of similar geometry repeatedly, offering opportunities for learning-based improvements. While past studies have focused on enhancing machining accuracy through part-to-part learning, this work shifts the focus to optimizing feedrate under servo error constraints. A data-driven model, trained online on prior machining data, predicts future servo errors and enables iterative feedrate optimization. Confidence in the model improves as more parts are machined, permitting progressively higher feedrates. Experimental results demonstrate significant speed gains within a few iterations, showcasing the potential of part-to-part learning for autonomously achieving faster machining without violating servo error constraints.
{"title":"Feedrate optimization based on part-to-part learning in repeated machining","authors":"Cheng-Hao Chou, Chenhui Shao, Chinedum E. Okwudire (2)","doi":"10.1016/j.cirp.2025.04.043","DOIUrl":"10.1016/j.cirp.2025.04.043","url":null,"abstract":"<div><div>Cutting operations often involve machining parts of similar geometry repeatedly, offering opportunities for learning-based improvements. While past studies have focused on enhancing machining accuracy through part-to-part learning, this work shifts the focus to optimizing feedrate under servo error constraints. A data-driven model, trained online on prior machining data, predicts future servo errors and enables iterative feedrate optimization. Confidence in the model improves as more parts are machined, permitting progressively higher feedrates. Experimental results demonstrate significant speed gains within a few iterations, showcasing the potential of part-to-part learning for autonomously achieving faster machining without violating servo error constraints.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 569-573"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611577","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.04.046
Lutfi Taner Tunc (2)
Manufacturing process chains of bladed disks are energy intense. Heat resistant properties of Inconel alloys make them very challenging to cut by conventional milling at roughing conditions, where excessive cutting forces and vibration arise. Abrasive waterjet machining (AWJM) offers several benefits in cutting of such materials. In the literature, 5-axis AWJM of blisks is not well studied for machining strategy, parameter selection and tool path generation. This paper presents a unified approach for development of 5-axis AWJM roughing of blisks. The proposed approach is demonstrated on a representative part made of Inconel 718.
{"title":"Tool path generation for precision roughing of BLISKS via abrasive waterjet machining","authors":"Lutfi Taner Tunc (2)","doi":"10.1016/j.cirp.2025.04.046","DOIUrl":"10.1016/j.cirp.2025.04.046","url":null,"abstract":"<div><div>Manufacturing process chains of bladed disks are energy intense. Heat resistant properties of Inconel alloys make them very challenging to cut by conventional milling at roughing conditions, where excessive cutting forces and vibration arise. Abrasive waterjet machining (AWJM) offers several benefits in cutting of such materials. In the literature, 5-axis AWJM of blisks is not well studied for machining strategy, parameter selection and tool path generation. This paper presents a unified approach for development of 5-axis AWJM roughing of blisks. The proposed approach is demonstrated on a representative part made of Inconel 718.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 563-567"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611576","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.04.088
Y. Altintas (1), M.Abdar Esfahani, B. Karimi, O. Gatenby
This paper presents a new trajectory generation algorithm that consists of a cascaded Finite Impulse Response (FIR) and a half-sine filter. FIR filter is used to set the acceleration, and the half-sine wave generates continuous velocity-acceleration and jerk motions along the tool path while avoiding the excitation of the machine vibrations. The algorithm allows for control of cornering errors between the discontinuous path segments. The algorithm is experimentally validated to damp the vibrations of a cantilevered beam, a mode of an industrial machine’s ball screw drive, and a tool path with sharp curvatures on a two-axis machine.
{"title":"Cascaded FIR and half-sine filter-based smooth trajectory generation algorithm","authors":"Y. Altintas (1), M.Abdar Esfahani, B. Karimi, O. Gatenby","doi":"10.1016/j.cirp.2025.04.088","DOIUrl":"10.1016/j.cirp.2025.04.088","url":null,"abstract":"<div><div>This paper presents a new trajectory generation algorithm that consists of a cascaded Finite Impulse Response (FIR) and a half-sine filter. FIR filter is used to set the acceleration, and the half-sine wave generates continuous velocity-acceleration and jerk motions along the tool path while avoiding the excitation of the machine vibrations. The algorithm allows for control of cornering errors between the discontinuous path segments. The algorithm is experimentally validated to damp the vibrations of a cantilevered beam, a mode of an industrial machine’s ball screw drive, and a tool path with sharp curvatures on a two-axis machine.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 559-562"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611575","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.04.091
Z. Dombovari , I. Laka , A. Bartfai , A. Karaca , E. Budak (1) , G. Stepan (1) , J. Munoa (1)
Robotic milling systems are increasingly used for light alloys and composites, but face challenges due to high dynamic flexibility of robots. A key issue is low-frequency chatter, linked to the robot's structural modes during high-speed operations. Therefore, this study deals with a dominant flexible mode with high tooth-passing frequencies, highlighting the influence of the directional factor. Negative directional factors can cause low-frequency chatter at high spindle speeds. Polar stability lobes show that optimal feed direction and radial engagement zones align with positive directional factors. The study shows that slotting operations assure a chatter free machining. Experimental validation confirms theoretical findings.
{"title":"Directional factor as the key factor for chatter free robotic milling of light alloys","authors":"Z. Dombovari , I. Laka , A. Bartfai , A. Karaca , E. Budak (1) , G. Stepan (1) , J. Munoa (1)","doi":"10.1016/j.cirp.2025.04.091","DOIUrl":"10.1016/j.cirp.2025.04.091","url":null,"abstract":"<div><div>Robotic milling systems are increasingly used for light alloys and composites, but face challenges due to high dynamic flexibility of robots. A key issue is low-frequency chatter, linked to the robot's structural modes during high-speed operations. Therefore, this study deals with a dominant flexible mode with high tooth-passing frequencies, highlighting the influence of the directional factor. Negative directional factors can cause low-frequency chatter at high spindle speeds. Polar stability lobes show that optimal feed direction and radial engagement zones align with positive directional factors. The study shows that slotting operations assure a chatter free machining. Experimental validation confirms theoretical findings.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 553-557"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611574","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.04.042
Hans-Christian Möhring (2), Michelle Engert, Kim Torben Werkle
Lightweight machine tool components provide the potential of improved system dynamics and reduced energy consumption. In this research, pre-stressed fiber-reinforced polymer concrete (PFRPC) structures were investigated, focusing on lightweight design and functional integration. An integrated strain measurement functionality was realized by embedding Fiber Bragg Gratings (FBG). Two versions of machine tool cantilever arms in the form of a Stewart platform were built using remaining plastic molds. The mechanical properties and operational characteristics were analyzed and compared with those of a conventional steel structure showing the high potential of the hybrid material with regard to the improved system dynamics.
{"title":"Material hybrid and sensor integrated lightweight machine tool components","authors":"Hans-Christian Möhring (2), Michelle Engert, Kim Torben Werkle","doi":"10.1016/j.cirp.2025.04.042","DOIUrl":"10.1016/j.cirp.2025.04.042","url":null,"abstract":"<div><div>Lightweight machine tool components provide the potential of improved system dynamics and reduced energy consumption. In this research, pre-stressed fiber-reinforced polymer concrete (PFRPC) structures were investigated, focusing on lightweight design and functional integration. An integrated strain measurement functionality was realized by embedding Fiber Bragg Gratings (FBG). Two versions of machine tool cantilever arms in the form of a Stewart platform were built using remaining plastic molds. The mechanical properties and operational characteristics were analyzed and compared with those of a conventional steel structure showing the high potential of the hybrid material with regard to the improved system dynamics.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 499-503"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611565","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.03.021
Phillip Stöcks-Morgan , Tobias Neuwirth , Achref Douiri , Simon R. Sebold , Anders Kaestner , Christoph Hartmann , Nora Leuning , Michael Schulz , Wolfram Volk (1)
Modern synchronous electric drives require magnetic anisotropy in their rotor, manufactured from non-oriented electrical steel. Conventionally, flux barriers are placed on electrical steel sheets by removing the material, creating small recesses. While the approach is magnetically effective, the rotor is mechanically weakened. Embossed flux barriers offer an approach to stiffen the rotor mechanically, increasing efficiency. The required micro-embossing was successfully produced on an industry-grade press for the first time. Magnetic characterisation of the samples using neutron grating interferometry and a single sheet tester shows that the novel technology is transferrable from the laboratory frame to large-scale industrial manufacturing processes.
{"title":"Towards large-scale production of improved magnetic flux guidance structures in non-grain-oriented electrical steel","authors":"Phillip Stöcks-Morgan , Tobias Neuwirth , Achref Douiri , Simon R. Sebold , Anders Kaestner , Christoph Hartmann , Nora Leuning , Michael Schulz , Wolfram Volk (1)","doi":"10.1016/j.cirp.2025.03.021","DOIUrl":"10.1016/j.cirp.2025.03.021","url":null,"abstract":"<div><div>Modern synchronous electric drives require magnetic anisotropy in their rotor, manufactured from non-oriented electrical steel. Conventionally, flux barriers are placed on electrical steel sheets by removing the material, creating small recesses. While the approach is magnetically effective, the rotor is mechanically weakened. Embossed flux barriers offer an approach to stiffen the rotor mechanically, increasing efficiency. The required micro-embossing was successfully produced on an industry-grade press for the first time. Magnetic characterisation of the samples using neutron grating interferometry and a single sheet tester shows that the novel technology is transferrable from the laboratory frame to large-scale industrial manufacturing processes.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 411-415"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611570","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.04.001
Salil Bapat , Tanvi Arey , John Vickers , Ajay P. Malshe (1)
This paper presents the application of crab-inspired design to develop a multifunctional robotic end effector for in-space servicing, assembly, and manufacturing (ISAM). It is demonstrated that crab hub and claw-inspired design, when 3D printed using carbon fiber composite, withstand space environments for severe vibration during launch and re-entry in and from space to earth in a vessel and vacuum. Testing this design demonstrated the end effector's versatility for tasks, including pick-and-place, twist-and-turn, and push-and-pull before and after the testing for space conditions. This study demonstrates the potential of novel bio-inspired principles to design and develop products for new commercial ISAM infrastructure.
{"title":"Bio-inspired multifunctional end effectors for in-space servicing, assembly and manufacturing (ISAM)","authors":"Salil Bapat , Tanvi Arey , John Vickers , Ajay P. Malshe (1)","doi":"10.1016/j.cirp.2025.04.001","DOIUrl":"10.1016/j.cirp.2025.04.001","url":null,"abstract":"<div><div>This paper presents the application of crab-inspired design to develop a multifunctional robotic end effector for in-space servicing, assembly, and manufacturing (ISAM). It is demonstrated that crab hub and claw-inspired design, when 3D printed using carbon fiber composite, withstand space environments for severe vibration during launch and re-entry in and from space to earth in a vessel and vacuum. Testing this design demonstrated the end effector's versatility for tasks, including pick-and-place, twist-and-turn, and push-and-pull before and after the testing for space conditions. This study demonstrates the potential of novel bio-inspired principles to design and develop products for new commercial ISAM infrastructure.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 185-189"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611884","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.03.032
Benjamin Bergmann (2), Jan Schenzel, Malte Kraeft
Basic knowledge of mechanical stresses is essential for an adapted tool design. A method for calculating internal stresses based on measured external stresses is shown. This eliminates the need for modelling the tool, chip and workpiece interaction as it is required in FE-based chip formation simulations. Thus, in-situ elastoplastic effects, such as springback or built-up edges, are directly considered. Using this approach, internal stresses of worn cutting tools are calculated at different wear states in order to understand tool wear. The experimental investigations show that for the machining of AISI1045+N principal stresses σ1 are the significant cause for tool failure.
{"title":"Tool failure: a method for stress calculation of worn cutting tools","authors":"Benjamin Bergmann (2), Jan Schenzel, Malte Kraeft","doi":"10.1016/j.cirp.2025.03.032","DOIUrl":"10.1016/j.cirp.2025.03.032","url":null,"abstract":"<div><div>Basic knowledge of mechanical stresses is essential for an adapted tool design. A method for calculating internal stresses based on measured external stresses is shown. This eliminates the need for modelling the tool, chip and workpiece interaction as it is required in FE-based chip formation simulations. Thus, in-situ elastoplastic effects, such as springback or built-up edges, are directly considered. Using this approach, internal stresses of worn cutting tools are calculated at different wear states in order to understand tool wear. The experimental investigations show that for the machining of AISI1045+<em>N</em> principal stresses <em>σ<sub>1</sub></em> are the significant cause for tool failure.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 123-126"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611808","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.03.022
Donghwan Noh , Jeong Whan Yoon (2)
This study introduces a reduced texture approach to efficiently describe the plastic behavior of AA6022-T43. By reducing the number of orientations in Finite Element (FE) analyses, the reduced texture approach improves computational efficiency while accurately predicting plastic responses. The approach calibrates a small number of crystallographic orientations using mechanical test results. By incorporating a kinematic hardening model, it captures Bauschinger effect, transient behavior, and permanent softening. Its predictive accuracy is also validated in springback, a critical challenge in sheet metal forming. The results confirm its potential as a computationally efficient alternative to continuum models for large scale engineering problems.
{"title":"Consideration of Bauschinger effect based on a reduced texture approach for improved springback prediction with computational efficiency","authors":"Donghwan Noh , Jeong Whan Yoon (2)","doi":"10.1016/j.cirp.2025.03.022","DOIUrl":"10.1016/j.cirp.2025.03.022","url":null,"abstract":"<div><div>This study introduces a reduced texture approach to efficiently describe the plastic behavior of AA6022-T43. By reducing the number of orientations in Finite Element (FE) analyses, the reduced texture approach improves computational efficiency while accurately predicting plastic responses. The approach calibrates a small number of crystallographic orientations using mechanical test results. By incorporating a kinematic hardening model, it captures Bauschinger effect, transient behavior, and permanent softening. Its predictive accuracy is also validated in springback, a critical challenge in sheet metal forming. The results confirm its potential as a computationally efficient alternative to continuum models for large scale engineering problems.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 351-355"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611893","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.04.097
Hitomi Yamaguchi (1) , Fukuo Hashimoto (1) , Eraldo da Silva (2) , Chi Fai Cheung (1)
Magnetic Field-Assisted Finishing (MAF) is a process that removes material by means of magnetic-abrasive tools suspended in a magnetic field. The unique behavior of magnetic-abrasive tools has given rise to various derivatives. This paper reviews the progression of MAF over the past century starting with a historical review, MAF fundamentals, and variations of MAF (e.g., polishing, edge finishing, and mass finishing). The status of MAF process modeling and a new approach to process modeling are introduced. The advantages and limitations of MAF are shown by discussing the material-removal characteristics. Lastly, potential applications and future directions for MAF research are suggested.
{"title":"Advances in magnetic field-assisted finishing","authors":"Hitomi Yamaguchi (1) , Fukuo Hashimoto (1) , Eraldo da Silva (2) , Chi Fai Cheung (1)","doi":"10.1016/j.cirp.2025.04.097","DOIUrl":"10.1016/j.cirp.2025.04.097","url":null,"abstract":"<div><div>Magnetic Field-Assisted Finishing (MAF) is a process that removes material by means of magnetic-abrasive tools suspended in a magnetic field. The unique behavior of magnetic-abrasive tools has given rise to various derivatives. This paper reviews the progression of MAF over the past century starting with a historical review, MAF fundamentals, and variations of MAF (e.g., polishing, edge finishing, and mass finishing). The status of MAF process modeling and a new approach to process modeling are introduced. The advantages and limitations of MAF are shown by discussing the material-removal characteristics. Lastly, potential applications and future directions for MAF research are suggested.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 2","pages":"Pages 921-944"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144663234","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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