This paper presents rotary tube flaring using a conical punch with grooves to achieve a high flaring limit and productivity. The grooved punch improves the flaring limit by suppressing bucking because it reduces the axial load as the tube contacts the punch intermittently. The effects of groove size and number on formability were investigated using tubes of aluminium alloy AA1070 and copper alloy C1220. The limit flaring ratio increased by up to 2.8 times compared to that of conventional press forming when the groove size and number were appropriate. The appropriate groove size varied depending on the tube material used.
{"title":"Rotary tube flaring using a conical punch with grooves for high forming limit and productivity","authors":"Shohei Kajikawa, Kiwamu Uchida, Takashi Kuboki (1)","doi":"10.1016/j.cirp.2025.04.004","DOIUrl":"10.1016/j.cirp.2025.04.004","url":null,"abstract":"<div><div>This paper presents rotary tube flaring using a conical punch with grooves to achieve a high flaring limit and productivity. The grooved punch improves the flaring limit by suppressing bucking because it reduces the axial load as the tube contacts the punch intermittently. The effects of groove size and number on formability were investigated using tubes of aluminium alloy AA1070 and copper alloy C1220. The limit flaring ratio increased by up to 2.8 times compared to that of conventional press forming when the groove size and number were appropriate. The appropriate groove size varied depending on the tube material used.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 387-391"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611899","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.2025.04.077
A. Verl (2), O. Jud
Preloaded ball screw drives are widely used in high-precision linear motion applications, particularly in machine tool feed drives. To compensate for the loss of preload due to wear over the service life and to maintain typical operational characteristics such as zero backlash and high rigidity, ball screws are usually preloaded to high values. However, this results in increased wear and friction, with a consequent increase in temperature. To address these issues, this paper introduces a novel double nut design for ball screws, featuring a passive preload adjustment mechanism, enabling reduced preload levels while enhancing operating characteristics and operational service life.
{"title":"Automatic preload adjustment for ball screw drives by means of a spring-loaded mechanism","authors":"A. Verl (2), O. Jud","doi":"10.1016/j.cirp.2025.04.077","DOIUrl":"10.1016/j.cirp.2025.04.077","url":null,"abstract":"<div><div>Preloaded ball screw drives are widely used in high-precision linear motion applications, particularly in machine tool feed drives. To compensate for the loss of preload due to wear over the service life and to maintain typical operational characteristics such as zero backlash and high rigidity, ball screws are usually preloaded to high values. However, this results in increased wear and friction, with a consequent increase in temperature. To address these issues, this paper introduces a novel double nut design for ball screws, featuring a passive preload adjustment mechanism, enabling reduced preload levels while enhancing operating characteristics and operational service life.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 483-486"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611562","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.2025.04.069
Nan Yu , Yifan Yuan , Zicheng Zhu , Ruslan Melentiev , Long Ye , James Tinkler , Lukas Raddatz , Stephen T. Newman (1)
Polycarbonate (PC) is emerging as one of the fastest-growing engineering plastics, but its potential for its application in a circular economy requires further investigation. This research explores the technical feasibility, carbon footprint, and economic impact of recycling injection moulding PC waste via fused deposition modelling (FDM) at a biotechnology manufacturer plant in the UK. The results show that recycling moulded PC scrap using FDM yields 3D printed parts with 88–98 % of virgin PC mechanical properties, produces nearly 70 % less carbon footprint, and saves up to 88 % of costs than utilizing virgin PC material.
{"title":"Sustainability of polycarbonate recycling via additive manufacturing","authors":"Nan Yu , Yifan Yuan , Zicheng Zhu , Ruslan Melentiev , Long Ye , James Tinkler , Lukas Raddatz , Stephen T. Newman (1)","doi":"10.1016/j.cirp.2025.04.069","DOIUrl":"10.1016/j.cirp.2025.04.069","url":null,"abstract":"<div><div>Polycarbonate (PC) is emerging as one of the fastest-growing engineering plastics, but its potential for its application in a circular economy requires further investigation. This research explores the technical feasibility, carbon footprint, and economic impact of recycling injection moulding PC waste via fused deposition modelling (FDM) at a biotechnology manufacturer plant in the UK. The results show that recycling moulded PC scrap using FDM yields 3D printed parts with 88–98 % of virgin PC mechanical properties, produces nearly 70 % less carbon footprint, and saves up to 88 % of costs than utilizing virgin PC material.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 61-65"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611831","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.2025.03.009
Urara Satake, Yuta Seguchi, Toshiyuki Enomoto (1)
Unique clamping mechanism adopted in double-sided polishing (DSP) enables free rotation of workpieces, which is critical for achieving uniform material removal. However, the DSP process has long faced the issue of non-rotating workpieces, resulting in tapered shapes—an issue particularly relevant to silicon wafer polishing. In this study, a kinetic analysis is conducted to investigate workpiece rotation during DSP and to clarify the mechanism underlying tapering. This analysis identifies key variables governing rotational speed and primary factors contributing to workpiece nonrotation. These findings are validated experimentally, and a practical approach to preventing tapering is proposed.
{"title":"Kinetic analysis of workpiece rotation behavior during double-sided polishing","authors":"Urara Satake, Yuta Seguchi, Toshiyuki Enomoto (1)","doi":"10.1016/j.cirp.2025.03.009","DOIUrl":"10.1016/j.cirp.2025.03.009","url":null,"abstract":"<div><div>Unique clamping mechanism adopted in double-sided polishing (DSP) enables free rotation of workpieces, which is critical for achieving uniform material removal. However, the DSP process has long faced the issue of non-rotating workpieces, resulting in tapered shapes—an issue particularly relevant to silicon wafer polishing. In this study, a kinetic analysis is conducted to investigate workpiece rotation during DSP and to clarify the mechanism underlying tapering. This analysis identifies key variables governing rotational speed and primary factors contributing to workpiece nonrotation. These findings are validated experimentally, and a practical approach to preventing tapering is proposed.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 435-439"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611553","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.2025.04.054
Dongdong Xu , Tiancheng Ai , Zifu Shen , Shuan Ma , Md Saddam Hossen , Zhirong Liao (2)
Silicon carbide fibre-reinforced titanium matrix composites are promising materials for lightweight and high-strength applications. However, their unique properties make them extremely difficult to machine. The present investigation proposes a laser-assisted grinding method to address this challenge and reveals distinct deformation mechanisms of the reinforced SiC fibres and titanium matrix by analysing the monitored machining process, surface properties, subsurface microstructure, and nanoscale deformation characteristics. It achieves improved surface integrity and enhanced machinability, attributed to the softening effect induced by additional thermal loads. This phenomenon transitions the SiC fibres from brittle states to semi-ductile conditions, facilitating fracture and improving overall machinability.
{"title":"Materials removal mechanism in laser-assisted grinding of SiC fibre-reinforced titanium alloy composite","authors":"Dongdong Xu , Tiancheng Ai , Zifu Shen , Shuan Ma , Md Saddam Hossen , Zhirong Liao (2)","doi":"10.1016/j.cirp.2025.04.054","DOIUrl":"10.1016/j.cirp.2025.04.054","url":null,"abstract":"<div><div>Silicon carbide fibre-reinforced titanium matrix composites are promising materials for lightweight and high-strength applications. However, their unique properties make them extremely difficult to machine. The present investigation proposes a laser-assisted grinding method to address this challenge and reveals distinct deformation mechanisms of the reinforced SiC fibres and titanium matrix by analysing the monitored machining process, surface properties, subsurface microstructure, and nanoscale deformation characteristics. It achieves improved surface integrity and enhanced machinability, attributed to the softening effect induced by additional thermal loads. This phenomenon transitions the SiC fibres from brittle states to semi-ductile conditions, facilitating fracture and improving overall machinability.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 417-421"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611571","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.2025.03.028
François Ducobu (2) , Thomas Beuscart , Valentin Dambly , Edouard Rivière-Lorphèvre , Gorka Ortiz-de-Zarate , Pedro-José Arrazola (1)
In aeronautics, mastering the drilling process is crucial to meet strict quality standards. While robots provide a cost-effective solution for drilling large, complex parts, challenges arise in metallic materials due to their low stiffness. This study establishes a systematic experimental method to improve hole quality during robotic drilling of aluminium alloys. Holes were drilled in plates in four positions and 64 postures using a 6 mm tool to analyse their influence on a new defect index. A static deflection compensation method was developed to improve hole quality, addressing static deflection issues narrowing the gap between robotic drilling and CNC machining.
{"title":"An experimental methodology to improve the robotic drilling of aluminium alloys","authors":"François Ducobu (2) , Thomas Beuscart , Valentin Dambly , Edouard Rivière-Lorphèvre , Gorka Ortiz-de-Zarate , Pedro-José Arrazola (1)","doi":"10.1016/j.cirp.2025.03.028","DOIUrl":"10.1016/j.cirp.2025.03.028","url":null,"abstract":"<div><div>In aeronautics, mastering the drilling process is crucial to meet strict quality standards. While robots provide a cost-effective solution for drilling large, complex parts, challenges arise in metallic materials due to their low stiffness. This study establishes a systematic experimental method to improve hole quality during robotic drilling of aluminium alloys. Holes were drilled in plates in four positions and 64 postures using a 6 mm tool to analyse their influence on a new defect index. A static deflection compensation method was developed to improve hole quality, addressing static deflection issues narrowing the gap between robotic drilling and CNC machining.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 103-107"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611804","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.2025.04.070
Ramazan Hakkı Namlu , Korcan Küçüköztaş , Hakan Kalkan , Bilgin Kaftanoğlu (1)
Invar 36, known for its low coefficient of thermal expansion, is widely used in applications like composite moulds, electronics, and optics. Although Wire Arc Additive Manufacturing (WAAM) offers high deposition rates and cost-effectiveness for Invar 36, it creates rough surface textures requiring machining as post-processing. In order to overcome Invar 36′s machinability challenges, Ultrasonic Vibration-Assisted Machining (UVAM) was applied for the first time on WAAM-fabricated Invar 36. The results showed that UVAM outperformed conventional machining in terms of cutting force, surface roughness and topography, subsurface microhardness and tool wear with improvements observed in both building and deposition directions.
{"title":"Ultrasonic vibration-assisted machining of invar 36 alloy manufactured by wire arc additive manufacturing","authors":"Ramazan Hakkı Namlu , Korcan Küçüköztaş , Hakan Kalkan , Bilgin Kaftanoğlu (1)","doi":"10.1016/j.cirp.2025.04.070","DOIUrl":"10.1016/j.cirp.2025.04.070","url":null,"abstract":"<div><div>Invar 36, known for its low coefficient of thermal expansion, is widely used in applications like composite moulds, electronics, and optics. Although Wire Arc Additive Manufacturing (WAAM) offers high deposition rates and cost-effectiveness for Invar 36, it creates rough surface textures requiring machining as post-processing. In order to overcome Invar 36′s machinability challenges, Ultrasonic Vibration-Assisted Machining (UVAM) was applied for the first time on WAAM-fabricated Invar 36. The results showed that UVAM outperformed conventional machining in terms of cutting force, surface roughness and topography, subsurface microhardness and tool wear with improvements observed in both building and deposition directions.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 87-91"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611801","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.2025.04.044
Malachi Landis, Muye Jia, Annalisa T. Taylor, Todd D. Murphey, Ping Guo (2)
Large-scale surfaces, such as ship hulls, face challenges in applying functional structures due to manufacturing constraints. This work presents a scalable approach using low-cost, autonomous robot swarms guided by an ergodic control framework to pattern micro-scale features on meter-scale metallic surfaces. The robots operate collaboratively to achieve density-specific coverage, optimizing surface functionalities like friction reduction and hydrodynamic performance. Experimental validation demonstrates the critical role of feature density in tribological performance, and an example application highlights the creation of gradient-density patterns. This innovative method unlocks new possibilities for functional surface patterning on large-scale structures with imprecise robots.
{"title":"Large-scale functional patterning using mobile robot swarms and ergodic control","authors":"Malachi Landis, Muye Jia, Annalisa T. Taylor, Todd D. Murphey, Ping Guo (2)","doi":"10.1016/j.cirp.2025.04.044","DOIUrl":"10.1016/j.cirp.2025.04.044","url":null,"abstract":"<div><div>Large-scale surfaces, such as ship hulls, face challenges in applying functional structures due to manufacturing constraints. This work presents a scalable approach using low-cost, autonomous robot swarms guided by an ergodic control framework to pattern micro-scale features on meter-scale metallic surfaces. The robots operate collaboratively to achieve density-specific coverage, optimizing surface functionalities like friction reduction and hydrodynamic performance. Experimental validation demonstrates the critical role of feature density in tribological performance, and an example application highlights the creation of gradient-density patterns. This innovative method unlocks new possibilities for functional surface patterning on large-scale structures with imprecise robots.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 511-515"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611567","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.2025.05.002
N. Anwer (1) , R. Stark (1) , F. Tao (2) , J.A. Erkoyuncu (2)
Digital twins are digital representations of real-world entities constantly fed by dynamic, bidirectional communication and updates throughout the lifecycle of these sophisticated paired systems. Developing digital twins in production engineering creates new avenues for engineering design in the context of digital transformation in manufacturing and sociotechnical systems. This paper reviews the foundational concepts, methodologies, and applications of digital twins in engineering design, covering both their architecture and development (engineering of digital twins), and their utilisation to enhance design activities (engineering with digital twins). An overview of the current state-of-the-art is presented, challenges are highlighted, and future research directions are addressed.
{"title":"Developing and leveraging digital twins in engineering design","authors":"N. Anwer (1) , R. Stark (1) , F. Tao (2) , J.A. Erkoyuncu (2)","doi":"10.1016/j.cirp.2025.05.002","DOIUrl":"10.1016/j.cirp.2025.05.002","url":null,"abstract":"<div><div>Digital twins are digital representations of real-world entities constantly fed by dynamic, bidirectional communication and updates throughout the lifecycle of these sophisticated paired systems. Developing digital twins in production engineering creates new avenues for engineering design in the context of digital transformation in manufacturing and sociotechnical systems. This paper reviews the foundational concepts, methodologies, and applications of digital twins in engineering design, covering both their architecture and development (engineering of digital twins), and their utilisation to enhance design activities (engineering with digital twins). An overview of the current state-of-the-art is presented, challenges are highlighted, and future research directions are addressed.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 2","pages":"Pages 843-868"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144663228","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.2025.05.004
A.T. Clare (1) , P. Woizeschke , B. Rankouhi , F.E. Pfefferkorn (1) , D. Bartels , M. Schmidt (1) , W.W. Wits (2)
Additive manufacturing has advanced rapidly since its origins in the 1980s. While some processes are now commercially viable, others remain experimental. A key ambition has been to combine multiple materials in a single part, enabling novel properties and overcoming traditional limitations of fabrication and assembly. Multi-material additive manufacturing offers a potential step change across industries, though scaling from lab to industry remains a challenge. This work explores the enabling technologies and science behind metal multi-material additive manufacturing and proposes how the research community can advance these innovations for meaningful industrial impact.
{"title":"Metal multi-material additive manufacturing: Overcoming barriers to implementation","authors":"A.T. Clare (1) , P. Woizeschke , B. Rankouhi , F.E. Pfefferkorn (1) , D. Bartels , M. Schmidt (1) , W.W. Wits (2)","doi":"10.1016/j.cirp.2025.05.004","DOIUrl":"10.1016/j.cirp.2025.05.004","url":null,"abstract":"<div><div>Additive manufacturing has advanced rapidly since its origins in the 1980s. While some processes are now commercially viable, others remain experimental. A key ambition has been to combine multiple materials in a single part, enabling novel properties and overcoming traditional limitations of fabrication and assembly. Multi-material additive manufacturing offers a potential step change across industries, though scaling from lab to industry remains a challenge. This work explores the enabling technologies and science behind metal multi-material additive manufacturing and proposes how the research community can advance these innovations for meaningful industrial impact.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 2","pages":"Pages 869-893"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144663229","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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