Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.04.005
Markus Bambach (2), Michael Robert Tucker
This study presents the design of a novel rotary PBF-LB/M machine where the recoater and gas system rotate synchronously with laser exposure. Unlike previous setups, the rotating nozzle covers only part of the powder bed, enabling higher localized gas velocities. CFD simulations indicate that a fine-mesh square grid improves flow uniformity with minimal powder disturbance. An angled recoater design supports stable rotary powder deposition. Trial builds, in-process measurements, and analyses of timing and powder efficiency demonstrate the system's effectiveness for annular parts, offering a significant speed advantage over rectilinear designs.
{"title":"Design and analyses of powder deposition, gas flow, and productivity for a rotary laser powder bed fusion system","authors":"Markus Bambach (2), Michael Robert Tucker","doi":"10.1016/j.cirp.2025.04.005","DOIUrl":"10.1016/j.cirp.2025.04.005","url":null,"abstract":"<div><div>This study presents the design of a novel rotary PBF-LB/M machine where the recoater and gas system rotate synchronously with laser exposure. Unlike previous setups, the rotating nozzle covers only part of the powder bed, enabling higher localized gas velocities. CFD simulations indicate that a fine-mesh square grid improves flow uniformity with minimal powder disturbance. An angled recoater design supports stable rotary powder deposition. Trial builds, in-process measurements, and analyses of timing and powder efficiency demonstrate the system's effectiveness for annular parts, offering a significant speed advantage over rectilinear designs.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 315-319"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611887","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.2025.04.074
Christian Baumann , Manisha Yerranagu , Weijun Zhang , Aishwarya Deshpande , Severin Maier , Stefan Gössinger , Masakazu Soshi , Friedrich Bleicher (1) , Frank E. Pfefferkorn (1)
The objective of this work is to compare three different hybrid metal additive-subtractive manufacturing processes to enable decision-making and future research. This was achieved by producing the same artifact out of 316L stainless steel with - Friction Surfacing, Wire Arc Additive Manufacturing, and Laser Powder Directed Energy Deposition. Key process outcomes including cycle time, resource consumption, distortion, energy consumption, microstructure, hardness, and tensile strength were analyzed. It was observed that: Friction Surfacing demonstrates higher hardness due to its solid-state nature; Wire Arc Additive Manufacturing offers lower cycle times and resource consumption; and Directed Energy Deposition provides near net shape geometries.
{"title":"Comparison of three hybrid metal additive-subtractive manufacturing processes","authors":"Christian Baumann , Manisha Yerranagu , Weijun Zhang , Aishwarya Deshpande , Severin Maier , Stefan Gössinger , Masakazu Soshi , Friedrich Bleicher (1) , Frank E. Pfefferkorn (1)","doi":"10.1016/j.cirp.2025.04.074","DOIUrl":"10.1016/j.cirp.2025.04.074","url":null,"abstract":"<div><div>The objective of this work is to compare three different hybrid metal additive-subtractive manufacturing processes to enable decision-making and future research. This was achieved by producing the same artifact out of 316L stainless steel with - Friction Surfacing, Wire Arc Additive Manufacturing, and Laser Powder Directed Energy Deposition. Key process outcomes including cycle time, resource consumption, distortion, energy consumption, microstructure, hardness, and tensile strength were analyzed. It was observed that: Friction Surfacing demonstrates higher hardness due to its solid-state nature; Wire Arc Additive Manufacturing offers lower cycle times and resource consumption; and Directed Energy Deposition provides near net shape geometries.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 321-325"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611888","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.2025.03.030
Chris V. Nielsen (2) , Paulo A.F. Martins (1) , Niels Bay (1)
A new set of slipline fields, along with a corresponding calculation procedure, offers an analytical solution to the flattening of asperities under high normal pressure and subsurface deformation. This new solution integrates existing slipline fields for asperity flattening at high normal pressures with those related to indentation and provides a statically admissible transition to uniform subsurface deformation under plane strain conditions. The calculation procedure effectively manages the transition from one slipline field to another, accounting for increments in both the real contact area ratio and the longitudinal strain associated with subsurface deformation. The new solution is validated against numerical simulations.
{"title":"Slipline solution to asperity deformation under combined high normal pressure and subsurface deformation","authors":"Chris V. Nielsen (2) , Paulo A.F. Martins (1) , Niels Bay (1)","doi":"10.1016/j.cirp.2025.03.030","DOIUrl":"10.1016/j.cirp.2025.03.030","url":null,"abstract":"<div><div>A new set of slipline fields, along with a corresponding calculation procedure, offers an analytical solution to the flattening of asperities under high normal pressure and subsurface deformation. This new solution integrates existing slipline fields for asperity flattening at high normal pressures with those related to indentation and provides a statically admissible transition to uniform subsurface deformation under plane strain conditions. The calculation procedure effectively manages the transition from one slipline field to another, accounting for increments in both the real contact area ratio and the longitudinal strain associated with subsurface deformation. The new solution is validated against numerical simulations.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 375-379"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611897","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.2025.03.031
Ludger Overmeyer (2) , Marvin Raupert , Matthias Pusch , Tjorben Griemsmann , André Katterfeld , Christoph Lotz
In-Space Manufacturing (ISM) needs material-efficient processes or the usage of locally available resources. This article presents two successfully applied approaches: Laser Powder Directed Energy Deposition (LP-DED) realized in microgravity on Earth for the first time using Ti-6Al-4V and substrate-free single layer powder bed fusion (PBF) under lunar gravity using LX-I50 regolith simulant. The Einstein-Elevator, a third-generation drop tower, is used to simulate the environmental conditions of space regarding gravity. The research results confirm the feasibility and open up new perspectives for space research, particularly concerning resource-efficient manufacturing technologies in future missions.
{"title":"Laser powder directed energy deposition and substrate-free single layer powder bed fusion under micro- and lunar gravity conditions","authors":"Ludger Overmeyer (2) , Marvin Raupert , Matthias Pusch , Tjorben Griemsmann , André Katterfeld , Christoph Lotz","doi":"10.1016/j.cirp.2025.03.031","DOIUrl":"10.1016/j.cirp.2025.03.031","url":null,"abstract":"<div><div>In-Space Manufacturing (ISM) needs material-efficient processes or the usage of locally available resources. This article presents two successfully applied approaches: Laser Powder Directed Energy Deposition (LP-DED) realized in microgravity on Earth for the first time using Ti-6Al-4V and substrate-free single layer powder bed fusion (PBF) under lunar gravity using LX-I50 regolith simulant. The Einstein-Elevator, a third-generation drop tower, is used to simulate the environmental conditions of space regarding gravity. The research results confirm the feasibility and open up new perspectives for space research, particularly concerning resource-efficient manufacturing technologies in future missions.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 297-301"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611902","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.2025.03.005
Kristian Martinsen (3) , Thawin Hart-Rawung , Jon Holmestad , Johan Andreas Stendal , Sverre Gulbrandsen-Dahl , Ole Runar Myhr
This paper shows how hybrid modeling combining a physics-based Precipitation Model and a data-driven Gaussian Process Regression model can be used to predict flow stress curves of different variants of AlMgSi1 alloys. The approach can be a step towards a methodology to manage higher variability in input material, such as remelted contaminated post-consumer aluminum scrap. Data from laboratory compression tests of six different compositional variations of AlMgSi1 with different contents of Si, Cu, and Mg was used. The proposed hybrid model aligns well with experimental results both within the training data range and inputs beyond the training range.
{"title":"Hybrid modelling predicting forming behavior with variations in AlMgSi1 alloys","authors":"Kristian Martinsen (3) , Thawin Hart-Rawung , Jon Holmestad , Johan Andreas Stendal , Sverre Gulbrandsen-Dahl , Ole Runar Myhr","doi":"10.1016/j.cirp.2025.03.005","DOIUrl":"10.1016/j.cirp.2025.03.005","url":null,"abstract":"<div><div>This paper shows how hybrid modeling combining a physics-based Precipitation Model and a data-driven Gaussian Process Regression model can be used to predict flow stress curves of different variants of AlMgSi1 alloys. The approach can be a step towards a methodology to manage higher variability in input material, such as remelted contaminated post-consumer aluminum scrap. Data from laboratory compression tests of six different compositional variations of AlMgSi1 with different contents of Si, Cu, and Mg was used. The proposed hybrid model aligns well with experimental results both within the training data range and inputs beyond the training range.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 369-373"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611896","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.2025.04.078
Julius Schoop, I.S. Jawahir (1)
While the physics of chip formation have been widely studied, there remains a need for greater qualitative and quantitative understanding of the way thermal and mechanical loads, and particularly their dynamic variability across length and time scales affect both the magnitude and variability of machining-induced residual stress (MIRS). This paper leverages an advanced in-situ characterization technique along with a physics-based process model to accurately and quickly predict key MIRS variables for aerospace alloys Inconel 718 and Ti-6Al4V. Our analysis clearly shows opportunities for digitally enabled predictability of engineered surface integrity to evaluate the fatigue performance of aerospace alloys more effectively.
{"title":"Physics-based modelling and validation of dynamically varying thermal and mechanical residual stress fields in finish machining of aerospace alloys","authors":"Julius Schoop, I.S. Jawahir (1)","doi":"10.1016/j.cirp.2025.04.078","DOIUrl":"10.1016/j.cirp.2025.04.078","url":null,"abstract":"<div><div>While the physics of chip formation have been widely studied, there remains a need for greater qualitative and quantitative understanding of the way thermal and mechanical loads, and particularly their dynamic variability across length and time scales affect both the magnitude and variability of machining-induced residual stress (MIRS). This paper leverages an advanced in-situ characterization technique along with a physics-based process model to accurately and quickly predict key MIRS variables for aerospace alloys Inconel 718 and Ti-6Al4V. Our analysis clearly shows opportunities for digitally enabled predictability of engineered surface integrity to evaluate the fatigue performance of aerospace alloys more effectively.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 109-112"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611805","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.2025.04.020
Thomas Bergs (2) , Hui Liu
This study investigates heat transfer to the tool and the cooling efficiency of flood cooling under various cutting conditions using experiments and simulations. An experimental apparatus was developed to measure tool temperature during side milling with cutting fluid. Furthermore, a computationally efficient multiscale simulation method, combining engagement simulation and orthogonal cutting simulation, is introduced to predict process forces and heat transfer to the tool. The findings indicate that accurate orthogonal cutting models enable the multiscale simulation to predict cutting forces and heat transfer. The higher computation speed compared to chip-forming simulations makes the proposed method well-suited for industrial applications.
{"title":"A novel approach to milling cutter temperature analysis with cutting fluid consideration","authors":"Thomas Bergs (2) , Hui Liu","doi":"10.1016/j.cirp.2025.04.020","DOIUrl":"10.1016/j.cirp.2025.04.020","url":null,"abstract":"<div><div>This study investigates heat transfer to the tool and the cooling efficiency of flood cooling under various cutting conditions using experiments and simulations. An experimental apparatus was developed to measure tool temperature during side milling with cutting fluid. Furthermore, a computationally efficient multiscale simulation method, combining engagement simulation and orthogonal cutting simulation, is introduced to predict process forces and heat transfer to the tool. The findings indicate that accurate orthogonal cutting models enable the multiscale simulation to predict cutting forces and heat transfer. The higher computation speed compared to chip-forming simulations makes the proposed method well-suited for industrial applications.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 119-122"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611807","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.2025.04.034
Ni Chen, Huiwen Chen, Bo Yan, Zhiyuan Mao, Ahsan Imran, Guolong Zhao, Ning He
Inconel 718 is widely used in aerospace due to thermomechanical properties, but machining causes rapid tool wear. This study develops a covalent diamond-nanographite-graphene (CDGG) tool using nanosecond lasers and flywheel cleavage to convert sp³ diamond into sp² graphene, welds it onto a carbide handle, and sharpens cutting edges. The friction-wear tests and cutting experiments show that CDGG tool’s apparent friction coefficient is 49–59 % lower than diamond tool, rake face wear depth is 55–65 % lower than diamond tool, 75–85 % lower than ceramic tool. Graphene forms self-lubricating layers, minimizes wear, and enhances Inconel 718 machining efficiency and tool durability.
{"title":"Improving cutting performance of nickel-based alloy by graphene modified diamond tools","authors":"Ni Chen, Huiwen Chen, Bo Yan, Zhiyuan Mao, Ahsan Imran, Guolong Zhao, Ning He","doi":"10.1016/j.cirp.2025.04.034","DOIUrl":"10.1016/j.cirp.2025.04.034","url":null,"abstract":"<div><div>Inconel 718 is widely used in aerospace due to thermomechanical properties, but machining causes rapid tool wear. This study develops a covalent diamond-nanographite-graphene (CDGG) tool using nanosecond lasers and flywheel cleavage to convert sp³ diamond into sp² graphene, welds it onto a carbide handle, and sharpens cutting edges. The friction-wear tests and cutting experiments show that CDGG tool’s apparent friction coefficient is 49–59 % lower than diamond tool, rake face wear depth is 55–65 % lower than diamond tool, 75–85 % lower than ceramic tool. Graphene forms self-lubricating layers, minimizes wear, and enhances Inconel 718 machining efficiency and tool durability.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 145-149"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611826","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.2025.03.001
Zhoumingju Jiang , Ang Liu (2) , Dawen Zhang , Xiwei Xu , Yun Dai
Large language models (LLMs) are increasingly used in design and manufacturing, yet directly employing general-purpose LLMs for conceptual design often leads to unmanufacturable concepts. This paper aims to adapt general-purpose LLMs for design-specific tasks. A new framework is presented to customize a general-purpose LLM into a design-specific model based on design-relevant data and Retrieval-Augmented Generation (RAG). Another complementary framework is presented to personalize the design-specific LLM by integrating design reasoning with prompting techniques. A design experiment, using patent documents as the design-relevant data, demonstrates that customization and personalization can improve LLM effectiveness in conceptual design, especially by enhancing concept feasibility.
{"title":"Customization and personalization of large language models for engineering design","authors":"Zhoumingju Jiang , Ang Liu (2) , Dawen Zhang , Xiwei Xu , Yun Dai","doi":"10.1016/j.cirp.2025.03.001","DOIUrl":"10.1016/j.cirp.2025.03.001","url":null,"abstract":"<div><div>Large language models (LLMs) are increasingly used in design and manufacturing, yet directly employing general-purpose LLMs for conceptual design often leads to unmanufacturable concepts. This paper aims to adapt general-purpose LLMs for design-specific tasks. A new framework is presented to customize a general-purpose LLM into a design-specific model based on design-relevant data and Retrieval-Augmented Generation (RAG). Another complementary framework is presented to personalize the design-specific LLM by integrating design reasoning with prompting techniques. A design experiment, using patent documents as the design-relevant data, demonstrates that customization and personalization can improve LLM effectiveness in conceptual design, especially by enhancing concept feasibility.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 191-195"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611834","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.2025.03.024
Song Yuan , Chi Fai Cheung (1) , Alborz Shokrani (2) , Zejin Zhan , Chunjin Wang
This paper presents an atomic-level flat polishing method based on hydroxyl (•OH) oxidation combining plasma modification and chemical mechanical polishing (CMP) of polycrystalline diamond (PCD). The PCD surface was firstly modified using •OH generated by He-based H2O2 plasma leading to the formation of an approximately 30 nm thick uniform oxidation layer on the PCD surface composed of carbon-oxygen mixed layer and oxygen-rich layer. Reactive force field molecular dynamics (ReaxFF MD) simulations explained the plasma modification mechanism. The modified layer was then removed using CMP resulting in an atomic-level flat surface with arithmetical mean height (Sa) of 0.366 nm.
{"title":"Atomic-level flat polishing of polycrystalline diamond by combining plasma modification and chemical mechanical polishing","authors":"Song Yuan , Chi Fai Cheung (1) , Alborz Shokrani (2) , Zejin Zhan , Chunjin Wang","doi":"10.1016/j.cirp.2025.03.024","DOIUrl":"10.1016/j.cirp.2025.03.024","url":null,"abstract":"<div><div>This paper presents an atomic-level flat polishing method based on hydroxyl (•OH) oxidation combining plasma modification and chemical mechanical polishing (CMP) of polycrystalline diamond (PCD). The PCD surface was firstly modified using •OH generated by He-based H<sub>2</sub>O<sub>2</sub> plasma leading to the formation of an approximately 30 nm thick uniform oxidation layer on the PCD surface composed of carbon-oxygen mixed layer and oxygen-rich layer. Reactive force field molecular dynamics (ReaxFF MD) simulations explained the plasma modification mechanism. The modified layer was then removed using CMP resulting in an atomic-level flat surface with arithmetical mean height (Sa) of 0.366 nm.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 441-445"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611554","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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