Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.04.083
Haoxuan Deng, Samir Khan, John Ahmet Erkoyuncu (2)
Deep learning is a powerful method for fault diagnosis, but its "black-box" nature raises concerns in critical applications. This paper presents an interpretable, lightweight method combining random convolution kernel transformation (ROCKET) with wavelet kernels, which offer systematic time-frequency analysis and intuitive insights. Principal component analysis (PCA) is used to extract relevant patterns, forming a health indicator that guides maintenance decisions. A case study on linear actuator fault diagnosis demonstrates the method's balance of interpretability and computational efficiency, making it a valuable tool for reliable asset health monitoring in resource-limited settings.
{"title":"Random wavelet kernels for interpretable fault diagnosis in industrial systems","authors":"Haoxuan Deng, Samir Khan, John Ahmet Erkoyuncu (2)","doi":"10.1016/j.cirp.2025.04.083","DOIUrl":"10.1016/j.cirp.2025.04.083","url":null,"abstract":"<div><div>Deep learning is a powerful method for fault diagnosis, but its \"black-box\" nature raises concerns in critical applications. This paper presents an interpretable, lightweight method combining random convolution kernel transformation (ROCKET) with wavelet kernels, which offer systematic time-frequency analysis and intuitive insights. Principal component analysis (PCA) is used to extract relevant patterns, forming a health indicator that guides maintenance decisions. A case study on linear actuator fault diagnosis demonstrates the method's balance of interpretability and computational efficiency, making it a valuable tool for reliable asset health monitoring in resource-limited settings.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 49-53"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611797","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.2025.04.066
Xiaoming Duan , Kun Zhang , Xiaodong Yang , Masanori Kunieda (1)
This paper aims to finish efficiently the surface of internal channels in additively manufactured parts. A novel electrochemical finishing (ECF) method was developed to finish curved channels of 5.8 mm in diameter. The tool electrode required for ECF was additively manufactured simultaneously with the internal channel. The finishing efficiency was significantly high because the electrolysis current flows uniformly at the same time along the channel. Furthermore, the tool electrode was rapidly removed through electrochemical dissolution by reversing the polarity after ECF. The gradient in material removal efficiency along the electrolyte flow ensures the stable removal of the tool electrode.
{"title":"Electrochemical finishing of internal channels in additively manufactured components using in-situ channel-conformal sacrificial tool electrodes","authors":"Xiaoming Duan , Kun Zhang , Xiaodong Yang , Masanori Kunieda (1)","doi":"10.1016/j.cirp.2025.04.066","DOIUrl":"10.1016/j.cirp.2025.04.066","url":null,"abstract":"<div><div>This paper aims to finish efficiently the surface of internal channels in additively manufactured parts. A novel electrochemical finishing (ECF) method was developed to finish curved channels of 5.8 mm in diameter. The tool electrode required for ECF was additively manufactured simultaneously with the internal channel. The finishing efficiency was significantly high because the electrolysis current flows uniformly at the same time along the channel. Furthermore, the tool electrode was rapidly removed through electrochemical dissolution by reversing the polarity after ECF. The gradient in material removal efficiency along the electrolyte flow ensures the stable removal of the tool electrode.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 221-225"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611839","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.2025.05.001
Jürgen Fleischer (1) , Dariusz Ceglarek (1) , Jörg Franke (2) , Christoph Herrmann (2)
Achieving CO₂-neutral transportation requires large-scale electric vehicle production, posing significant manufacturing challenges. Electric vehicles consist of components with multi-physical functionalities and intricate interdependencies that exceed the capabilities of current production systems. This paper examines key drivetrain components, including power supply systems, batteries, power electronics, and traction motors. It reviews state-of-the-art manufacturing and associated challenges. Analytical and numerical modeling approaches as well as product-specific trends are highlighted. Furthermore, the paper puts emphasis on life cycle assessment (LCA) and life cycle engineering (LCE), as electric drivetrains pose distinct challenges compared to conventional drivetrains. Lastly, future research demands for electric mobility production technology and component-specific research fields are outlined.
{"title":"Production technologies and systems for electric mobility","authors":"Jürgen Fleischer (1) , Dariusz Ceglarek (1) , Jörg Franke (2) , Christoph Herrmann (2)","doi":"10.1016/j.cirp.2025.05.001","DOIUrl":"10.1016/j.cirp.2025.05.001","url":null,"abstract":"<div><div>Achieving CO₂-neutral transportation requires large-scale electric vehicle production, posing significant manufacturing challenges. Electric vehicles consist of components with multi-physical functionalities and intricate interdependencies that exceed the capabilities of current production systems. This paper examines key drivetrain components, including power supply systems, batteries, power electronics, and traction motors. It reviews state-of-the-art manufacturing and associated challenges. Analytical and numerical modeling approaches as well as product-specific trends are highlighted. Furthermore, the paper puts emphasis on life cycle assessment (LCA) and life cycle engineering (LCE), as electric drivetrains pose distinct challenges compared to conventional drivetrains. Lastly, future research demands for electric mobility production technology and component-specific research fields are outlined.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 2","pages":"Pages 1047-1072"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144663093","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.2025.04.060
Koji Ota , Daisuke Kono (2) , Masahiko Mori (1)
This paper proposes a machine tool design methodology that balances the heat capacity of the machine structure with heat inflow, ensuring a uniform temperature distribution and reducing thermal displacement caused by environmental temperature changes. Heat inflow at each part of the structure is quantitatively determined based on the heat capacity distribution. The target structure is systematically selected through thermal sensitivity evaluation. This methodology was applied to a turning center, and experimental results demonstrated that a uniform temperature distribution was achieved, reducing thermal displacement.
{"title":"Thermal displacement reduction based on heat transfer characteristics under environmental temperature changes","authors":"Koji Ota , Daisuke Kono (2) , Masahiko Mori (1)","doi":"10.1016/j.cirp.2025.04.060","DOIUrl":"10.1016/j.cirp.2025.04.060","url":null,"abstract":"<div><div>This paper proposes a machine tool design methodology that balances the heat capacity of the machine structure with heat inflow, ensuring a uniform temperature distribution and reducing thermal displacement caused by environmental temperature changes. Heat inflow at each part of the structure is quantitatively determined based on the heat capacity distribution. The target structure is systematically selected through thermal sensitivity evaluation. This methodology was applied to a turning center, and experimental results demonstrated that a uniform temperature distribution was achieved, reducing thermal displacement.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 493-497"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611564","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.2025.04.014
Mohammadreza Chehrehzad, Ismail Lazoglu (1)
Runout in CNC machine tools is a critical factor affecting machining accuracy, surface finish, and tool wear. This article introduces an innovative sensorless approach for monitoring in-process runout during milling. In-process runout is assessed using an industrial edge device that analyzes spindle current and torque signals, which exhibit a strong correlation with dynamometer data. Frequency-domain analysis of the spindle current and torque signals enables sensorless monitoring of runout in real-time. Experimental results on milling of TiAl6V4 demonstrate the potential of this non-intrusive approach for in-process runout detection, offering a cost-effective solution to enhance machining efficiency and precision in smart manufacturing.
{"title":"Sensorless in-process runout monitoring in milling via an industrial edge device","authors":"Mohammadreza Chehrehzad, Ismail Lazoglu (1)","doi":"10.1016/j.cirp.2025.04.014","DOIUrl":"10.1016/j.cirp.2025.04.014","url":null,"abstract":"<div><div>Runout in CNC machine tools is a critical factor affecting machining accuracy, surface finish, and tool wear. This article introduces an innovative sensorless approach for monitoring in-process runout during milling. In-process runout is assessed using an industrial edge device that analyzes spindle current and torque signals, which exhibit a strong correlation with dynamometer data. Frequency-domain analysis of the spindle current and torque signals enables sensorless monitoring of runout in real-time. Experimental results on milling of TiAl6V4 demonstrate the potential of this non-intrusive approach for in-process runout detection, offering a cost-effective solution to enhance machining efficiency and precision in smart manufacturing.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 99-102"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611803","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.2025.04.024
Amir Malakizadi , Rachid M'Saoubi (1)
A dislocation-based flow stress model is proposed to describe the behavior of Alloy 718 fabricated using laser-based and electron-beam powder bed fusion methods. This physics-based model is adaptive to microstructural variations including the size and volume fraction of precipitates, crystallographic texture, grain size and the density of immobile dislocations. Coupled with data from thermodynamic and kinetic simulations, as well as insights from advanced characterization methods, this model provides a framework for assessing machinability of additively manufactured Alloy 718. The predicted cutting forces and chip shape parameters showed a good agreement with the corresponding measurements.
{"title":"A physics-based flow stress model for cutting simulation of additively manufactured Alloy 718","authors":"Amir Malakizadi , Rachid M'Saoubi (1)","doi":"10.1016/j.cirp.2025.04.024","DOIUrl":"10.1016/j.cirp.2025.04.024","url":null,"abstract":"<div><div>A dislocation-based flow stress model is proposed to describe the behavior of Alloy 718 fabricated using laser-based and electron-beam powder bed fusion methods. This physics-based model is adaptive to microstructural variations including the size and volume fraction of <span><math><msup><mrow><mrow><mi>γ</mi></mrow></mrow><mrow><mo>″</mo></mrow></msup></math></span> precipitates, crystallographic texture, grain size and the density of immobile dislocations. Coupled with data from thermodynamic and kinetic simulations, as well as insights from advanced characterization methods, this model provides a framework for assessing machinability of additively manufactured Alloy 718. The predicted cutting forces and chip shape parameters showed a good agreement with the corresponding measurements.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 113-117"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611806","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}
A novel frequency domain approach is proposed to estimate the cutting force coefficients through a dedicated analytical formulation. The method uses the amplitudes of the Fourier series harmonics and does not require any phase information. When compared to the average cutting force approach, the proposed method gives better accuracy even when few data points are used along the tool path. The method is verified by machining Ti6Al4V alloy with a variable pitch-helix tool using straight and slope cutting; the predicted coefficients are also validated by comparing them with those obtained using commercial machining simulation software.
{"title":"A novel multi-harmonic and phase-independent estimation of cutting force coefficients","authors":"Zekai Murat Kilic , Joshua Priest , Sabino Ayvar-Soberanis , Srichand Hinduja (1)","doi":"10.1016/j.cirp.2025.04.021","DOIUrl":"10.1016/j.cirp.2025.04.021","url":null,"abstract":"<div><div>A novel frequency domain approach is proposed to estimate the cutting force coefficients through a dedicated analytical formulation. The method uses the amplitudes of the Fourier series harmonics and does not require any phase information. When compared to the average cutting force approach, the proposed method gives better accuracy even when few data points are used along the tool path. The method is verified by machining Ti6Al4V alloy with a variable pitch-helix tool using straight and slope cutting; the predicted coefficients are also validated by comparing them with those obtained using commercial machining simulation software.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 127-131"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611809","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.2025.04.035
Nanya Li , Changkun Sun , Hanlin Zheng , S.K. Ong (1)
Graded cellular structures offer a controlled distribution of material, resulting in customization of stiffness. This paper presents a novel design optimization method for graded topological structures based on differentiable Voronoi diagrams. Unlike conventional discrete Voronoi diagrams, which lack differentiability to solve gradient-based structure optimization problems, the proposed method leverages a SoftMax activation function to tune pixel regions into continuous stress field defined in a Euclidean space. Furthermore, pseudo site points and metric tensor have been applied for rotating and distorting Voronoi cells, so as to achieve much higher specific strength and energy absorption property than traditional optimization methods.
{"title":"Design optimization of graded cellular structures for additive manufacturing via differentiable Voronoi diagram","authors":"Nanya Li , Changkun Sun , Hanlin Zheng , S.K. Ong (1)","doi":"10.1016/j.cirp.2025.04.035","DOIUrl":"10.1016/j.cirp.2025.04.035","url":null,"abstract":"<div><div>Graded cellular structures offer a controlled distribution of material, resulting in customization of stiffness. This paper presents a novel design optimization method for graded topological structures based on differentiable Voronoi diagrams. Unlike conventional discrete Voronoi diagrams, which lack differentiability to solve gradient-based structure optimization problems, the proposed method leverages a SoftMax activation function to tune pixel regions into continuous stress field defined in a Euclidean space. Furthermore, pseudo site points and metric tensor have been applied for rotating and distorting Voronoi cells, so as to achieve much higher specific strength and energy absorption property than traditional optimization methods.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 161-165"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611829","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.2025.04.022
Hussein Mishbak , Mohamed H. Hassan , Evangelos Daskalakis , Abdalla M. Omar , Dino M. Freitas , Wajira Mirihanage , Paul Mativenga (2) , Prasad Potluri , Paulo Bartolo (1)
Scaffolds play a key role in bone repair and should have a degradation rate that matches the rate of bone regeneration. However, the slow degradation of bone tissue scaffolds is a major challenge. This research investigated the degradation rate of Polyethylene terephthalate glycol (PETG) bone-tissue scaffolds printed with different lay-up patterns (0/45, 0/60/120, and 0/90). Degradation kinetics were explored using design-informed processing conditions, considering variations in the printing path length, crystallinity and fibre contact points. The findings revealed that changing scaffold lay-up increased the degradation rate by up to 50 % while maintaining compressive modulus. The research contributes a new and novel material-independent approach for controlling scaffolds degradation rate and mechanical performance.
{"title":"Accelerated degradation of 3D-printed PETG bone–tissue scaffolds via geometrical control","authors":"Hussein Mishbak , Mohamed H. Hassan , Evangelos Daskalakis , Abdalla M. Omar , Dino M. Freitas , Wajira Mirihanage , Paul Mativenga (2) , Prasad Potluri , Paulo Bartolo (1)","doi":"10.1016/j.cirp.2025.04.022","DOIUrl":"10.1016/j.cirp.2025.04.022","url":null,"abstract":"<div><div>Scaffolds play a key role in bone repair and should have a degradation rate that matches the rate of bone regeneration. However, the slow degradation of bone tissue scaffolds is a major challenge. This research investigated the degradation rate of Polyethylene terephthalate glycol (PETG) bone-tissue scaffolds printed with different lay-up patterns (0/45, 0/60/120, and 0/90). Degradation kinetics were explored using design-informed processing conditions, considering variations in the printing path length, crystallinity and fibre contact points. The findings revealed that changing scaffold lay-up increased the degradation rate by up to 50 % while maintaining compressive modulus. The research contributes a new and novel material-independent approach for controlling scaffolds degradation rate and mechanical performance.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 327-331"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611889","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.2025.03.043
Putong Kang, Brett Wadman, Kornel Ehmann, Jian Cao (1)
This study explores Incremental Sheet Forming (ISF) to fabricate mold liners as part of a newly proposed molding system for small-scale applications. A modified toolpath strategy, leveraging the tooltip geometry and feature skeleton, enabled the creation of high-quality features. The rotating forming tool introduced wavy surface textures, enhancing the functionality of the molded products. Polydimethylsiloxane (PDMS) molded with ISF-formed liners demonstrated good dimensional accuracy and smooth surface finishes. Compared to stereolithography (SLA)-printed liners, ISF-formed liners offered easier demolding and broader material compatibility. Future work will address high-pressure applications and more complex mold designs to expand industrial applicability.
{"title":"Mold liners produced by incremental sheet forming","authors":"Putong Kang, Brett Wadman, Kornel Ehmann, Jian Cao (1)","doi":"10.1016/j.cirp.2025.03.043","DOIUrl":"10.1016/j.cirp.2025.03.043","url":null,"abstract":"<div><div>This study explores Incremental Sheet Forming (ISF) to fabricate mold liners as part of a newly proposed molding system for small-scale applications. A modified toolpath strategy, leveraging the tooltip geometry and feature skeleton, enabled the creation of high-quality features. The rotating forming tool introduced wavy surface textures, enhancing the functionality of the molded products. Polydimethylsiloxane (PDMS) molded with ISF-formed liners demonstrated good dimensional accuracy and smooth surface finishes. Compared to stereolithography (SLA)-printed liners, ISF-formed liners offered easier demolding and broader material compatibility. Future work will address high-pressure applications and more complex mold designs to expand industrial applicability.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 363-367"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611895","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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