Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.03.016
Seulah Park , Sukkyung Kang , Dong Geun Kim , Sanha Kim (2)
Dishing is a critical defect in chemical mechanical polishing (CMP) that affects the mechanical reliability and electrical performance of hybrid bonding interfaces in semiconductor packaging. This study explores that micro-structured pad with well-defined asperity design can minimize CMP dishing. A theoretical model identifies asperity area, height variation, and modulus as key factors influencing contact pressure and dishing. Experimental results validate the model, demonstrating a 69% reduction in dishing with a soft cylindrical pad compared to a commercial pad. This improvement is attributed to increased real contact area and uniform pressure distribution due to minimized height variation and material compliance.
{"title":"Mitigation of Cu dishing in chemical mechanical polishing using micro-structured pads","authors":"Seulah Park , Sukkyung Kang , Dong Geun Kim , Sanha Kim (2)","doi":"10.1016/j.cirp.2025.03.016","DOIUrl":"10.1016/j.cirp.2025.03.016","url":null,"abstract":"<div><div>Dishing is a critical defect in chemical mechanical polishing (CMP) that affects the mechanical reliability and electrical performance of hybrid bonding interfaces in semiconductor packaging. This study explores that micro-structured pad with well-defined asperity design can minimize CMP dishing. A theoretical model identifies asperity area, height variation, and modulus as key factors influencing contact pressure and dishing. Experimental results validate the model, demonstrating a 69% reduction in dishing with a soft cylindrical pad compared to a commercial pad. This improvement is attributed to increased real contact area and uniform pressure distribution due to minimized height variation and material compliance.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 465-469"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611559","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.2025.04.059
Tobias Recker, Annika Raatz (2)
This study introduces a scalable control framework for Cooperative Multi-Robot Systems (cMRS), enhancing flexibility in manufacturing by adapting single-robot motion sequences to multi-robot setups. The framework addresses kinematic overdetermination via a Virtual Robot Model (VRM), which centralizes motion specification without straining computational resources, allowing seamless scaling. Experimental results demonstrate that cMRS configurations with varying robot numbers can achieve object transport and handling with accuracy comparable to single-robot systems under admittance control. Although larger configurations show increased maximum tracking errors, average accuracy remains stable, demonstrating the framework’s effectiveness for scalable cooperative robotics.
{"title":"Design and control of flexible handling systems based on mobile cooperative multi-robot-systems","authors":"Tobias Recker, Annika Raatz (2)","doi":"10.1016/j.cirp.2025.04.059","DOIUrl":"10.1016/j.cirp.2025.04.059","url":null,"abstract":"<div><div>This study introduces a scalable control framework for Cooperative Multi-Robot Systems (cMRS), enhancing flexibility in manufacturing by adapting single-robot motion sequences to multi-robot setups. The framework addresses kinematic overdetermination via a Virtual Robot Model (VRM), which centralizes motion specification without straining computational resources, allowing seamless scaling. Experimental results demonstrate that cMRS configurations with varying robot numbers can achieve object transport and handling with accuracy comparable to single-robot systems under admittance control. Although larger configurations show increased maximum tracking errors, average accuracy remains stable, demonstrating the framework’s effectiveness for scalable cooperative robotics.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 25-29"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611793","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.2025.04.080
Bence Tipary , Gábor Erdős (2) , Zsolt Kemény
The mainstream of diagnostic approaches of printed circuit board assemblies is optimised for large-scale industrial production, and is less suited for repair and maintenance during later stages of the product life-cycle. Main challenges include sparse documentation, small batch sizes and high product diversity, to which existing solutions are too costly, bulky or parameter-sensitive for industrial use. The paper presents a novel approach using computer vision, visual servoing and digital twins for robotic positioning of a measuring probe head. Subject to patent application, the method has proven its feasibility and affordability in live industrial practice with 99.80% success rate.
{"title":"Constellation-based robotic visual servoing method for fault diagnosis of used printed circuit board assemblies","authors":"Bence Tipary , Gábor Erdős (2) , Zsolt Kemény","doi":"10.1016/j.cirp.2025.04.080","DOIUrl":"10.1016/j.cirp.2025.04.080","url":null,"abstract":"<div><div>The mainstream of diagnostic approaches of printed circuit board assemblies is optimised for large-scale industrial production, and is less suited for repair and maintenance during later stages of the product life-cycle. Main challenges include sparse documentation, small batch sizes and high product diversity, to which existing solutions are too costly, bulky or parameter-sensitive for industrial use. The paper presents a novel approach using computer vision, visual servoing and digital twins for robotic positioning of a measuring probe head. Subject to patent application, the method has proven its feasibility and affordability in live industrial practice with 99.80% success rate.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 43-47"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611796","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}
Aluminium-based SiC particle-reinforced metal matrix composites are widely used in engineering applications due to their exceptional mechanical properties. However, their machining remains challenging due to the mismatch of material properties between the brittle SiC particles and the ductile aluminium matrix, causing tool wear and surface damage. To mitigate these issues, laser inverse problem scanning is utilised to strategically melt the top layer aluminium matrix, allowing the SiC particles to sink and promoting more ductile Al-matrix. The strategic hybrid laser milling approach optimises particle sinking, reduces tool wear and enhances surface integrity by minimising particle fracture, pullout and refining microstructure.
{"title":"Sub-surface sinking effect of reinforcement particle in laser assisted machining of metal matrix composites","authors":"Omkar Mypati , Zhirong Liao (2) , Shusong Zan , Rachid M'Saoubi (1) , Dragos Axinte (1)","doi":"10.1016/j.cirp.2025.04.041","DOIUrl":"10.1016/j.cirp.2025.04.041","url":null,"abstract":"<div><div>Aluminium-based SiC particle-reinforced metal matrix composites are widely used in engineering applications due to their exceptional mechanical properties. However, their machining remains challenging due to the mismatch of material properties between the brittle SiC particles and the ductile aluminium matrix, causing tool wear and surface damage. To mitigate these issues, laser inverse problem scanning is utilised to strategically melt the top layer aluminium matrix, allowing the SiC particles to sink and promoting more ductile Al-matrix. The strategic hybrid laser milling approach optimises particle sinking, reduces tool wear and enhances surface integrity by minimising particle fracture, pullout and refining microstructure.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 93-97"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611802","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}
The growing demand for sustainable end-of-life management in aerospace has increased the need for robotic disassembly. This paper presents a novel pipeline for aircraft engine disassembly, operating in automatic and semi-automatic modes with state-of-the-art vision-based techniques. The key contributions are: (1) a method combining the Segment Anything Model (SAM) with YOLO for detecting removable bolts, independent of engine model and adaptable to various worn bolt types using vision-only perception; and (2) a SAM-based approach for estimating task orientation, ensuring precise tool alignment. Validated in simulations and real-world tests, the pipeline demonstrates high accuracy and adaptability for solutions in aerospace manufacturing.
{"title":"Vision-based robotic disassembly of aircraft engines with YOLO-SAM: a novel method for task orientation estimation","authors":"Angelo Moroncelli , Sylvain Populus , Armand Rossi , Emanuele Carpanzano (1) , Loris Roveda","doi":"10.1016/j.cirp.2025.04.063","DOIUrl":"10.1016/j.cirp.2025.04.063","url":null,"abstract":"<div><div>The growing demand for sustainable end-of-life management in aerospace has increased the need for robotic disassembly. This paper presents a novel pipeline for aircraft engine disassembly, operating in automatic and semi-automatic modes with state-of-the-art vision-based techniques. The key contributions are: (1) a method combining the Segment Anything Model (SAM) with YOLO for detecting removable bolts, independent of engine model and adaptable to various worn bolt types using vision-only perception; and (2) a SAM-based approach for estimating task orientation, ensuring precise tool alignment. Validated in simulations and real-world tests, the pipeline demonstrates high accuracy and adaptability for solutions in aerospace manufacturing.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 55-59"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611798","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}
The printability assessment of high-aspect-ratio structures in additive manufacturing is critical for ensuring dimensional accuracy and functional properties. This study proposes a method to evaluate print quality by quantifying metrics, including accuracy, shape fidelity and line edge quality, using advanced imaging and predictive analysis. A printability index is developed to relate these metrics to process parameters, here applied to Aerosol Jet® Printing. By validating structures’ quality and optimizing parameters, the index effectively improves process stability, reduces defects, and enhances structural precision. This approach provides a robust tool for process optimization, ensuring consistent results in complex high-aspect-ratio designs, further advancing printing scalability and reproducibility.
{"title":"Printability assessment and modelling for process optimization of 3D Aerosol Jet® printed high aspect ratio microstructures","authors":"Elisabetta Ceretti (2) , Mohit Sharma , Eleonora Ferraris (2) , Paola Serena Ginestra , Miriam Seiti","doi":"10.1016/j.cirp.2025.04.062","DOIUrl":"10.1016/j.cirp.2025.04.062","url":null,"abstract":"<div><div>The printability assessment of high-aspect-ratio structures in additive manufacturing is critical for ensuring dimensional accuracy and functional properties. This study proposes a method to evaluate print quality by quantifying metrics, including accuracy, shape fidelity and line edge quality, using advanced imaging and predictive analysis. A printability index is developed to relate these metrics to process parameters, here applied to Aerosol Jet® Printing. By validating structures’ quality and optimizing parameters, the index effectively improves process stability, reduces defects, and enhances structural precision. This approach provides a robust tool for process optimization, ensuring consistent results in complex high-aspect-ratio designs, further advancing printing scalability and reproducibility.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 287-291"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611885","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.2025.04.019
Lin Gu (2) , Lijie Jiang , Kelin Li , Xiaoka Wang
Diamond/Al composites are promising materials for thermal management, but the presence of diamond particles makes them extremely difficult-to-cut. To address this challenge, blasting erosion arc machining (BEAM) is suggested for its high efficiency. The removal mechanism, particularly the influence of diamond particles, was first studied through magnetohydrodynamics and heat transfer simulations. Further analysis revealed how differences in the thermal properties between the reinforcements and the matrix result in distinct solid-liquid-gas phase transitions. The debris morphology and composition were analyzed to further clarify the removal mechanism. Experiments confirmed the high-efficiency machining performance of BEAM in diamond/Al composites.
{"title":"Removal mechanism of diamond/Al composites in blasting erosion arc machining","authors":"Lin Gu (2) , Lijie Jiang , Kelin Li , Xiaoka Wang","doi":"10.1016/j.cirp.2025.04.019","DOIUrl":"10.1016/j.cirp.2025.04.019","url":null,"abstract":"<div><div>Diamond/Al composites are promising materials for thermal management, but the presence of diamond particles makes them extremely difficult-to-cut. To address this challenge, blasting erosion arc machining (BEAM) is suggested for its high efficiency. The removal mechanism, particularly the influence of diamond particles, was first studied through magnetohydrodynamics and heat transfer simulations. Further analysis revealed how differences in the thermal properties between the reinforcements and the matrix result in distinct solid-liquid-gas phase transitions. The debris morphology and composition were analyzed to further clarify the removal mechanism. Experiments confirmed the high-efficiency machining performance of BEAM in diamond/Al composites.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 245-249"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611843","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.2025.04.067
Florian Morczinek , Martin Dix (3) , Rafael Wertheim (1)
To optimize the workpiece removal process and maximize the fraction of reusable abrasive particles, it is necessary to ascertain the characteristics of the high-pressure suspension jet process, including the kinetic energy of the particles in the jet. In this study, the particle velocity and the change in their size were measured and analyzed. It was found that due to breakage the average particle size decreases by up to 35 % during the acceleration process in the nozzle. The results showed that the particle size has insignificant influence on particle velocity, while the kinetic energy of an average particle decreased by up to 72 %.
{"title":"Characterization of the high-pressure suspension jet for efficient cutting and abrasive circularity","authors":"Florian Morczinek , Martin Dix (3) , Rafael Wertheim (1)","doi":"10.1016/j.cirp.2025.04.067","DOIUrl":"10.1016/j.cirp.2025.04.067","url":null,"abstract":"<div><div>To optimize the workpiece removal process and maximize the fraction of reusable abrasive particles, it is necessary to ascertain the characteristics of the high-pressure suspension jet process, including the kinetic energy of the particles in the jet. In this study, the particle velocity and the change in their size were measured and analyzed. It was found that due to breakage the average particle size decreases by up to 35 % during the acceleration process in the nozzle. The results showed that the particle size has insignificant influence on particle velocity, while the kinetic energy of an average particle decreased by up to 72 %.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 333-337"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611890","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}
This work optimises and analyses the processing of a new lean tool steel (Osprey® HWTS 50), using laser powder bed fusion (PBF-LB) at 80 °C preheating and different layer thicknesses (20 µm vs. 40 µm). Full density is reached via a higher volumetric energy density (VED) for the lower layer thickness. After optimising contours, reducing surface roughness and ensuring no microcrack formation, the tensile properties are rather comparable in both cases (UTS ∼ 1500 MPa, elongation ∼ 10–12%). However, yield strength, hardness and residual stresses are slightly higher for the lower layer thickness. The geometrical freedom for intricate features is nevertheless comparable.
{"title":"Effect of layer thickness in laser powder bed fusion of HWTS 50 hot work tool steel","authors":"Sasan Dadbakhsh , Sinesh Vadakkekkara , Ashik Mansingh Anila , Lorena Emanuelli , Massimo Pellizzari , Faraz Deirmina","doi":"10.1016/j.cirp.2025.03.004","DOIUrl":"10.1016/j.cirp.2025.03.004","url":null,"abstract":"<div><div>This work optimises and analyses the processing of a new lean tool steel (Osprey® HWTS 50), using laser powder bed fusion (PBF-LB) at 80 °C preheating and different layer thicknesses (20 µm vs. 40 µm). Full density is reached via a higher volumetric energy density (VED) for the lower layer thickness. After optimising contours, reducing surface roughness and ensuring no microcrack formation, the tensile properties are rather comparable in both cases (UTS ∼ 1500 MPa, elongation ∼ 10–12%). However, yield strength, hardness and residual stresses are slightly higher for the lower layer thickness. The geometrical freedom for intricate features is nevertheless comparable.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 293-296"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611901","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.2025.03.040
Carlos M.A. Silva , João P.M. Pragana , Rui F.V. Sampaio , Ivo M.F. Bragança , Paulo A.F. Martins (1)
This paper presents a novel double-flush riveting process for creating lap joints in sheet metal parts. The process involves punching, forging, and shaving to produce countersunk holes with precise geometry, followed by compression of cylindrical rivets into the holes of two overlapped sheet parts to create form-closed mechanical interlocks. Experimental and numerical analyses examine the influence of the primary process parameters on interlock quality and required forming and destructive forces. The investigation is a step forward in joining technology by offering a simple alternative to welding, bonding, and mechanical joining, with seamless integration into multistage forming tools.
{"title":"Advanced double-flush riveting for multistage forming tools","authors":"Carlos M.A. Silva , João P.M. Pragana , Rui F.V. Sampaio , Ivo M.F. Bragança , Paulo A.F. Martins (1)","doi":"10.1016/j.cirp.2025.03.040","DOIUrl":"10.1016/j.cirp.2025.03.040","url":null,"abstract":"<div><div>This paper presents a novel double-flush riveting process for creating lap joints in sheet metal parts. The process involves punching, forging, and shaving to produce countersunk holes with precise geometry, followed by compression of cylindrical rivets into the holes of two overlapped sheet parts to create form-closed mechanical interlocks. Experimental and numerical analyses examine the influence of the primary process parameters on interlock quality and required forming and destructive forces. The investigation is a step forward in joining technology by offering a simple alternative to welding, bonding, and mechanical joining, with seamless integration into multistage forming tools.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 399-403"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611904","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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