Pub Date : 2025-01-01Epub Date: 2025-05-05DOI: 10.1016/j.cirp.2025.03.014
E. Simonetto , S. Bruschi (1) , A. Ghiotti (1) , A. Schrepfer , W. Volk (1)
Blanking at sub-zero temperatures using liquid nitrogen is presented as an innovative method for cutting non-oriented electrical steel (NOES) to reduce the plastic deformation required for separation and minimize microstructural changes that could impact the sheet's characteristics. Three process temperatures – room temperature, -50 °C, and -100 °C – were investigated, and the results were evaluated in terms of cut edge quality, microstructural features, and hardness evolution. The results demonstrated a significant reduction in the plastically deformed zone and hardness variation at the cut edge, accompanied by decreased microstructural misorientation, highlighting this method's potential to minimize the drawbacks of conventional blanking.
{"title":"Sub-zero temperature blanking of non-oriented electrical steels","authors":"E. Simonetto , S. Bruschi (1) , A. Ghiotti (1) , A. Schrepfer , W. Volk (1)","doi":"10.1016/j.cirp.2025.03.014","DOIUrl":"10.1016/j.cirp.2025.03.014","url":null,"abstract":"<div><div>Blanking at sub-zero temperatures using liquid nitrogen is presented as an innovative method for cutting non-oriented electrical steel (NOES) to reduce the plastic deformation required for separation and minimize microstructural changes that could impact the sheet's characteristics. Three process temperatures – room temperature, -50 °C, and -100 °C – were investigated, and the results were evaluated in terms of cut edge quality, microstructural features, and hardness evolution. The results demonstrated a significant reduction in the plastically deformed zone and hardness variation at the cut edge, accompanied by decreased microstructural misorientation, highlighting this method's potential to minimize the drawbacks of conventional blanking.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 345-349"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611892","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 : 2025-01-01Epub Date: 2025-04-29DOI: 10.1016/j.cirp.2025.03.037
Debajyoti Bhaduri , Karan A. Baramate , Soumya Gangopadhyay , Thomas E. Davies
The viability of using ball milled (BM) Ti-6Al-4V machining chips for fabricating parts by binder jetting (BJT) additive manufacturing is reported. The built parts’ density, roughness, microhardness and compressive strength are compared with BJT parts made from gas atomised (GA) powder. Sintered BM and GA parts exhibit comparable relative density (93–95 %), while microhardness of the former is almost twice of the latter. Equiaxed grains with greater β-phase fraction are observed in the BM parts’ microstructure. The BM compression test pieces exhibit brittle fracture due to greater strain hardening of the BM particles, compared to the plastic deformation of the GA specimens.
{"title":"Circular manufacturing of binder jetting additive parts from Ti-6Al-4 V machining chips","authors":"Debajyoti Bhaduri , Karan A. Baramate , Soumya Gangopadhyay , Thomas E. Davies","doi":"10.1016/j.cirp.2025.03.037","DOIUrl":"10.1016/j.cirp.2025.03.037","url":null,"abstract":"<div><div>The viability of using ball milled (BM) Ti-6Al-4V machining chips for fabricating parts by binder jetting (BJT) additive manufacturing is reported. The built parts’ density, roughness, microhardness and compressive strength are compared with BJT parts made from gas atomised (GA) powder. Sintered BM and GA parts exhibit comparable relative density (93–95 %), while microhardness of the former is almost twice of the latter. Equiaxed grains with greater β-phase fraction are observed in the BM parts’ microstructure. The BM compression test pieces exhibit brittle fracture due to greater strain hardening of the BM particles, compared to the plastic deformation of the GA specimens.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 303-307"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611903","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 : 2025-01-01Epub Date: 2025-04-29DOI: 10.1016/j.cirp.2025.04.072
Mohit Law (2)
Classifying defects is difficult when spindle bearings have multiple faults that interact with each other and result in the measured vibrations exhibiting cyclo- and non-stationarity. For such cases, this paper shows that the Ramanujan sum when used as a basis to construct filter banks helps decompose the signal into its individual components that makes it possible to estimate hidden defect periods. Illustrative examples with different spindle types show how filter banks can identify periods not obvious in the signal’s Fourier spectra, or in spectrograms, or even those left unclassified by the envelope spectrum method or the empirical mode decomposition method.
{"title":"Finding hidden spindle bearing defect periods using Ramanujan filter banks","authors":"Mohit Law (2)","doi":"10.1016/j.cirp.2025.04.072","DOIUrl":"10.1016/j.cirp.2025.04.072","url":null,"abstract":"<div><div>Classifying defects is difficult when spindle bearings have multiple faults that interact with each other and result in the measured vibrations exhibiting cyclo- and non-stationarity. For such cases, this paper shows that the Ramanujan sum when used as a basis to construct filter banks helps decompose the signal into its individual components that makes it possible to estimate hidden defect periods. Illustrative examples with different spindle types show how filter banks can identify periods not obvious in the signal’s Fourier spectra, or in spectrograms, or even those left unclassified by the envelope spectrum method or the empirical mode decomposition method.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 477-481"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611561","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 : 2025-01-01Epub Date: 2025-05-02DOI: 10.1016/j.cirp.2025.04.090
Mathias Liewald (2), Stephan Nießner
Punched sheet metal parts are shear cut at least once during production. Shearing sheets generally cause dislocation movements in the lattice structure, leading to inhomogeneous stress distributions and thus part warpage. Although strategies for avoiding warpage are principally known, flatness tolerances of high-quality punched parts often cannot be met since specific and experience-based adjustments of machine parameters are required. This paper presents a method for automatically compensating for warpage of perforated blanks by adapting part holder forces acting in a innovative punching tool. Cutting force measurements from previous process sequences and a machine learning model are considered for this adaption.
{"title":"Compensation of blank warpage in punching processes through an innovative adaptive control system for adjusting part holder forces","authors":"Mathias Liewald (2), Stephan Nießner","doi":"10.1016/j.cirp.2025.04.090","DOIUrl":"10.1016/j.cirp.2025.04.090","url":null,"abstract":"<div><div>Punched sheet metal parts are shear cut at least once during production. Shearing sheets generally cause dislocation movements in the lattice structure, leading to inhomogeneous stress distributions and thus part warpage. Although strategies for avoiding warpage are principally known, flatness tolerances of high-quality punched parts often cannot be met since specific and experience-based adjustments of machine parameters are required. This paper presents a method for automatically compensating for warpage of perforated blanks by adapting part holder forces acting in a innovative punching tool. Cutting force measurements from previous process sequences and a machine learning model are considered for this adaption.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 523-527"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611572","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 : 2025-01-01Epub Date: 2025-05-01DOI: 10.1016/j.cirp.2025.04.093
Shuntaro Yamato
This paper proposes an approach to cutting force reconstruction in milling combining a machine learning model with cutting process simulations. The machine learning model is developed in the feature space of amplitude spectra associated with the tooth-passing components extracted through the moving Fourier transform of time series data. Subsequently, the cutting force time waveform is reconstructed by integrating the estimated amplitude spectra with phase information provided by a cutting simulator. This approach facilitates efficient model construction compared to directly using time waveforms for training. It also enables straightforward multiple-sensor fusion using the ML model, thereby enhancing estimation performance.
{"title":"Cutting force reconstruction in milling by multi-sensor fusion with hybrid aid of process and data-driven models","authors":"Shuntaro Yamato","doi":"10.1016/j.cirp.2025.04.093","DOIUrl":"10.1016/j.cirp.2025.04.093","url":null,"abstract":"<div><div>This paper proposes an approach to cutting force reconstruction in milling combining a machine learning model with cutting process simulations. The machine learning model is developed in the feature space of amplitude spectra associated with the tooth-passing components extracted through the moving Fourier transform of time series data. Subsequently, the cutting force time waveform is reconstructed by integrating the estimated amplitude spectra with phase information provided by a cutting simulator. This approach facilitates efficient model construction compared to directly using time waveforms for training. It also enables straightforward multiple-sensor fusion using the ML model, thereby enhancing estimation performance.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 517-521"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611568","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 : 2025-01-01Epub Date: 2025-05-05DOI: 10.1016/j.cirp.2025.04.048
Felix Finkeldey , Makoto Kato , Petra Wiederkehr (2) , Yasuhiro Kakinuma (2)
Using data-based approaches, accurate predictions of thermal deformations, which can significantly affect the quality of manufactured components, can be enabled. However, a sufficient amount of data with maximised information content is necessary for efficient training. In this paper, an approach for optimising sensor configurations for predicting thermal deformations is presented. From initially 300 temperature sensors, the number of required sensors was significantly reduced while maintaining predictive accuracy. Furthermore, a pattern for sensor placement was identified, providing the potential for an efficient sensor layout that enables cost-effective data acquisition and improved monitoring of machining and wear progression of machine tool components.
{"title":"AI-based sensor layout for predicting thermal deformations of CFRP machine tools","authors":"Felix Finkeldey , Makoto Kato , Petra Wiederkehr (2) , Yasuhiro Kakinuma (2)","doi":"10.1016/j.cirp.2025.04.048","DOIUrl":"10.1016/j.cirp.2025.04.048","url":null,"abstract":"<div><div>Using data-based approaches, accurate predictions of thermal deformations, which can significantly affect the quality of manufactured components, can be enabled. However, a sufficient amount of data with maximised information content is necessary for efficient training. In this paper, an approach for optimising sensor configurations for predicting thermal deformations is presented. From initially 300 temperature sensors, the number of required sensors was significantly reduced while maintaining predictive accuracy. Furthermore, a pattern for sensor placement was identified, providing the potential for an efficient sensor layout that enables cost-effective data acquisition and improved monitoring of machining and wear progression of machine tool components.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 505-509"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611566","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}
In this paper, the interaction between forced and chatter vibrations through flank-workpiece interference is studied. The effect of the well-known process damping, which occurs due to the contact between the flank face and the workpiece, on the chatter stability has been studied broadly. However, this contact should occur by forced vibration also, which has not been studied much in the literature. Due to this contact, forced vibration should suppress chatter, and vice versa; interaction should occur. A model is constructed to evaluate this interaction, and the interactive effects are clarified through simulations and experiments.
{"title":"Interaction between forced and chatter vibrations through flank-workpiece interference","authors":"Takehiro Hayasaka (2), Hayato Murai, Kyungki Lee, Eiji Shamoto (1)","doi":"10.1016/j.cirp.2025.04.064","DOIUrl":"10.1016/j.cirp.2025.04.064","url":null,"abstract":"<div><div>In this paper, the interaction between forced and chatter vibrations through flank-workpiece interference is studied. The effect of the well-known process damping, which occurs due to the contact between the flank face and the workpiece, on the chatter stability has been studied broadly. However, this contact should occur by forced vibration also, which has not been studied much in the literature. Due to this contact, forced vibration should suppress chatter, and vice versa; interaction should occur. A model is constructed to evaluate this interaction, and the interactive effects are clarified through simulations and experiments.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 575-578"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611578","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 : 2025-01-01Epub Date: 2025-04-18DOI: 10.1016/j.cirp.2025.04.023
Amin Bagherzadeh , Ozkan Gokcekaya , Erhan Budak (1)
The anisotropic properties of additively manufactured materials cause variations in surface finish, cutting forces, and machinability due to directional differences in material properties. This creates challenges in tool path selection for five-axis machining to achieve optimal process conditions. Additionally, traditional models and methods for process modelling and simulation often fail, leading to significant errors, as they do not account for material anisotropy. This work investigates the material behaviour during machining of additively manufactured materials, proposes a directional-adaptive flow stress model for accurate process modelling and simulation, and introduces an adaptive tool path selection strategy tailored for milling of additively manufactured materials.
{"title":"Directional-adaptive approach in machining of additively manufactured Inconel 718","authors":"Amin Bagherzadeh , Ozkan Gokcekaya , Erhan Budak (1)","doi":"10.1016/j.cirp.2025.04.023","DOIUrl":"10.1016/j.cirp.2025.04.023","url":null,"abstract":"<div><div>The anisotropic properties of additively manufactured materials cause variations in surface finish, cutting forces, and machinability due to directional differences in material properties. This creates challenges in tool path selection for five-axis machining to achieve optimal process conditions. Additionally, traditional models and methods for process modelling and simulation often fail, leading to significant errors, as they do not account for material anisotropy. This work investigates the material behaviour during machining of additively manufactured materials, proposes a directional-adaptive flow stress model for accurate process modelling and simulation, and introduces an adaptive tool path selection strategy tailored for milling of additively manufactured materials.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 81-85"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611800","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 : 2025-01-01Epub Date: 2025-05-01DOI: 10.1016/j.cirp.2025.04.075
Yu Gu , Runming Tao , Chris Yuan (2) , Hong C Zhang (1) , Michael Hauschild (1)
Maxwell-type dry processing has emerged as a promising manufacturing technology for high-areal-loading Li-ion battery electrodes, offering a significant advantage by eliminating the use of the toxic and costly NMP solvent. This study developed a cradle-to-grave life-cycle-assessment model to evaluate the environmental impacts of this innovative technology, benchmarking the results against the conventional NMP-based technique for a configured 42 kWh NMC622-graphite battery pack. The findings reveal that the dry-processing method merits a 4.8% lower energy consumption and achieves environmental impacts up to 47.5% lower in 12 out of 13 categories, highlighting its environmental benefits compared with the NMP-based manufacturing processes.
{"title":"A cradle-to-grave life-cycle-assessment of dry-processed Li-ion batteries for electric vehicles","authors":"Yu Gu , Runming Tao , Chris Yuan (2) , Hong C Zhang (1) , Michael Hauschild (1)","doi":"10.1016/j.cirp.2025.04.075","DOIUrl":"10.1016/j.cirp.2025.04.075","url":null,"abstract":"<div><div>Maxwell-type dry processing has emerged as a promising manufacturing technology for high-areal-loading Li-ion battery electrodes, offering a significant advantage by eliminating the use of the toxic and costly NMP solvent. This study developed a cradle-to-grave life-cycle-assessment model to evaluate the environmental impacts of this innovative technology, benchmarking the results against the conventional NMP-based technique for a configured 42 kWh NMC622-graphite battery pack. The findings reveal that the dry-processing method merits a 4.8% lower energy consumption and achieves environmental impacts up to 47.5% lower in 12 out of 13 categories, highlighting its environmental benefits compared with the NMP-based manufacturing processes.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 73-76"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611799","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}
Sustainability-by-Design requires information and communication technologies (ICTs) capable of integrating design engineering, manufacturing processes, materials, and sustainability considerations. Currently, methodologies for assessing environmental sustainability, such as product life cycle assessment, are often implemented too late in the design process, reducing opportunities for early intervention. Integrating environmental sustainability modeling in computer-aided systems (CAx) allows engineers to concurrently evaluate trade-offs between technical performance and environmental impact, facilitating informed decision-making during embodiment design stages. Using a prosthetic device produced via material jetting additive manufacturing as case study, we demonstrate the transformative role of advanced CAx tools capable of analyzing trade-offs among competing objectives.
{"title":"Enabling sustainability-by-design with multi-disciplinary computer aided systems","authors":"Iñigo Flores Ituarte , Emanuele Pagone , Amirmohammad Daareyni , Samniroshan Thayapararajah , Guido Tosello (2)","doi":"10.1016/j.cirp.2025.03.019","DOIUrl":"10.1016/j.cirp.2025.03.019","url":null,"abstract":"<div><div>Sustainability-by-Design requires information and communication technologies (ICTs) capable of integrating design engineering, manufacturing processes, materials, and sustainability considerations. Currently, methodologies for assessing environmental sustainability, such as product life cycle assessment, are often implemented too late in the design process, reducing opportunities for early intervention. Integrating environmental sustainability modeling in computer-aided systems (CAx) allows engineers to concurrently evaluate trade-offs between technical performance and environmental impact, facilitating informed decision-making during embodiment design stages. Using a prosthetic device produced via material jetting additive manufacturing as case study, we demonstrate the transformative role of advanced CAx tools capable of analyzing trade-offs among competing objectives.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 209-213"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611837","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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