Pub Date : 2025-04-04DOI: 10.1016/j.cirpj.2025.03.013
Christian Argenti , Hansen Li , Miguel A. Funes-Lora , Aditya Pandey , Albert J. Shih , Chunlei K. Song
Advancing cutting-based surgical technologies requires the knowledge of the interaction between tools and soft biomaterials which undergo large deformations before failure. The pendulum-based scribing is applied to deform the soft porcine clot and quantify its interaction with the tool. The pendulum apparatus has a 307 mm long swing arm with a 1 mm diameter blunt tip steel wire for scribing the porcine clot, which is cured by mixing the porcine whole blood and coagulant in a mold. After curing, the cover of the clot mold was removed to expose grooves of porcine clots in a fixture. Clot specimens were scribed at maximum speeds of 0.76 and 1.47 m/s. The cutting force was captured by a piezoelectric dynamometer beneath the clot fixture. High-speed video was recorded to observe the clot cutting and deformation during the scribing process. A smoothed particle Galerkin (SPG) model of the scribing process was developed to gain insights into the material deformation and to identify clot material properties for scribing by validating with experimentally measured scribing forces. The model exhibited concordance with experimental cutting force data, showing a deviation of 6.9 % at 0.76 m/s and 8.3 % at 1.47 m/s.
{"title":"Smoothed particle Galerkin modeling and experimental validation of pendulum-based scribing of porcine clots","authors":"Christian Argenti , Hansen Li , Miguel A. Funes-Lora , Aditya Pandey , Albert J. Shih , Chunlei K. Song","doi":"10.1016/j.cirpj.2025.03.013","DOIUrl":"10.1016/j.cirpj.2025.03.013","url":null,"abstract":"<div><div>Advancing cutting-based surgical technologies requires the knowledge of the interaction between tools and soft biomaterials which undergo large deformations before failure. The pendulum-based scribing is applied to deform the soft porcine clot and quantify its interaction with the tool. The pendulum apparatus has a 307 mm long swing arm with a 1 mm diameter blunt tip steel wire for scribing the porcine clot, which is cured by mixing the porcine whole blood and coagulant in a mold. After curing, the cover of the clot mold was removed to expose grooves of porcine clots in a fixture. Clot specimens were scribed at maximum speeds of 0.76 and 1.47 m/s. The cutting force was captured by a piezoelectric dynamometer beneath the clot fixture. High-speed video was recorded to observe the clot cutting and deformation during the scribing process. A smoothed particle Galerkin (SPG) model of the scribing process was developed to gain insights into the material deformation and to identify clot material properties for scribing by validating with experimentally measured scribing forces. The model exhibited concordance with experimental cutting force data, showing a deviation of 6.9 % at 0.76 m/s and 8.3 % at 1.47 m/s.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"59 ","pages":"Pages 186-193"},"PeriodicalIF":4.6,"publicationDate":"2025-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143768044","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Tool steels are widely used as dies and tools due to their exceptional properties. However, cracking and wear can significantly impact the performance and longevity of the tools. The possibility of repairing the damaged parts by Directed Energy Deposition (DED) results in an extended tool life and improved environmental impact compared to traditional techniques. To this purpose, the current study aims at investigating the processability of K340 cold work steel by DED. To study the processing window, based on a face-centered composite design, double-tracks with different sets of nozzle travel speed (), laser power (P), and carrier gas flow rate () were deposited. Deposits were characterized by scanning electron microscopy (SEM), coherence scanning interferometry (CSI), and micro-instrumented indentation, and quantitative analysis of influence factors was performed by ANOVA and response surface methodology. The results showed that increasing P and decreasing resulted in an improved surface roughness. However, surface features describing extreme values, such as Sp and Sz, showed the presence of not fully incorporated particles. Additionally, showed no significant effect on parameters describing the average roughness, such as Sa, Sq and Sdq. Cross-section analysis revealed that almost defect-free deposits can be made with a porosity fraction area of as low as 0.04 %. However, the deposited material showed a different microstructure than that of the substrate, and heat affected zones were also observed. By increasing P, the dilution tended to rise from 5 % to 36 %. The laser power was shown to be the main parameter affecting the dilution. The process optimization to have the best possible combination of high geometrical accuracy and low surface roughness and low defect level was implemented and validated by experimental results. By investigating the processing window and optimizing the process, this study facilitates the application of DED as a repairing process of K340 tools and contributes to sustainable manufacturing.
{"title":"Surface topography and cross-section analysis of K340 cold work tool steel double-tracks deposited by directed energy deposition technique","authors":"Mohammad Saleh Kenevisi , Federico Simone Gobber , Giacomo Maculotti , Gianfranco Genta , Maurizio Galetto , Sara Biamino , Daniele Ugues","doi":"10.1016/j.cirpj.2025.03.011","DOIUrl":"10.1016/j.cirpj.2025.03.011","url":null,"abstract":"<div><div>Tool steels are widely used as dies and tools due to their exceptional properties. However, cracking and wear can significantly impact the performance and longevity of the tools. The possibility of repairing the damaged parts by Directed Energy Deposition (DED) results in an extended tool life and improved environmental impact compared to traditional techniques. To this purpose, the current study aims at investigating the processability of K340 cold work steel by DED. To study the processing window, based on a face-centered composite design, double-tracks with different sets of nozzle travel speed (<span><math><msub><mrow><mi>v</mi></mrow><mrow><mi>N</mi></mrow></msub></math></span>), laser power (<em>P</em>), and carrier gas flow rate (<span><math><msub><mrow><mi>V</mi></mrow><mrow><mi>cg</mi></mrow></msub></math></span>) were deposited. Deposits were characterized by scanning electron microscopy (SEM), coherence scanning interferometry (CSI), and micro-instrumented indentation, and quantitative analysis of influence factors was performed by ANOVA and response surface methodology. The results showed that increasing <em>P</em> and decreasing <span><math><msub><mrow><mi>v</mi></mrow><mrow><mi>N</mi></mrow></msub></math></span> resulted in an improved surface roughness. However, surface features describing extreme values, such as <em>Sp</em> and <em>Sz</em>, showed the presence of not fully incorporated particles. Additionally, <span><math><msub><mrow><mi>V</mi></mrow><mrow><mi>cg</mi></mrow></msub></math></span> showed no significant effect on parameters describing the average roughness, such as <em>Sa</em>, <em>Sq</em> and <em>Sdq</em>. Cross-section analysis revealed that almost defect-free deposits can be made with a porosity fraction area of as low as 0.04 %. However, the deposited material showed a different microstructure than that of the substrate, and heat affected zones were also observed. By increasing <em>P</em>, the dilution tended to rise from 5 % to 36 %. The laser power was shown to be the main parameter affecting the dilution. The process optimization to have the best possible combination of high geometrical accuracy and low surface roughness and low defect level was implemented and validated by experimental results. By investigating the processing window and optimizing the process, this study facilitates the application of DED as a repairing process of K340 tools and contributes to sustainable manufacturing.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"59 ","pages":"Pages 158-169"},"PeriodicalIF":4.6,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143746804","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-04-02DOI: 10.1016/j.cirpj.2025.03.004
Jagannath Suresh , Gagan K. Goyal , Haozheng Wang , Lei Zuo
Laser powder bed fusion (L-PBF) method of additive manufacturing is typically applied to metallic alloys for structural applications. It may be applied to fabricate components of functional materials such as the binary Mg2Si alloys with appropriate parameter optimization for energy harvesting applications. The L-PBF processing of such a material requires critical control over the input laser power and scan speed to minimise the structural defects in the end product. We developed a Computational Fluid Dynamics (CFD) model in MATLAB to simulate the thermal profiles of the dynamic molten pool to modulate the applied laser power and the scan speed. The material’s melting point and the conventional sintering temperature were used as the baseline numbers to scrutinize the suitable laser parameters. The CFD modeled laser parameters were tested to fabricate L-PBF processed Mg2Si and the conventional sintering temperature of 1173 K was found to be a better limiting criterion than the melting point to prevent excessive balling and Mg vaporization. The fluidic flow velocity and its effect on the melt pool dynamics were observed experimentally. The microstructural variations in such materials are known to affect their thermoelectric performance, and the high cooling rate during the solidification in the L-PBF process favors dendritic growth, which differs from the conventionally fabricated samples possessing equiaxed grains. The microstructure evolution from the rapid solidification of the melt pool was predicted using the phase field analysis considering the effects of perturbation and the strength of anisotropy. A computational domain was simulated with an initial nucleation site of diameter 0.35 µm, and the directional dendritic growth patterns for different laser power and scan rates were obtained and analyzed. A comparable interdendritic spacing between the simulated primary dendritic arms (0.46 µm) and that measured within the L-PBF processed sample (0.57 µm) as seen under a Scanning Electron Microscope (SEM) is obtained, indicating the model’s efficacy in simulating the possible growth mechanism. The phase evolution of the L-PBF processed Mg2Si component with the implication on its thermoelectric performance and the challenges in its fabrication are discussed.
{"title":"Melt pool dynamics and microstructural growth prediction of additively manufactured thermoelectric material","authors":"Jagannath Suresh , Gagan K. Goyal , Haozheng Wang , Lei Zuo","doi":"10.1016/j.cirpj.2025.03.004","DOIUrl":"10.1016/j.cirpj.2025.03.004","url":null,"abstract":"<div><div>Laser powder bed fusion (L-PBF) method of additive manufacturing is typically applied to metallic alloys for structural applications. It may be applied to fabricate components of functional materials such as the binary Mg<sub>2</sub>Si alloys with appropriate parameter optimization for energy harvesting applications. The L-PBF processing of such a material requires critical control over the input laser power and scan speed to minimise the structural defects in the end product. We developed a Computational Fluid Dynamics (CFD) model in MATLAB to simulate the thermal profiles of the dynamic molten pool to modulate the applied laser power and the scan speed. The material’s melting point and the conventional sintering temperature were used as the baseline numbers to scrutinize the suitable laser parameters. The CFD modeled laser parameters were tested to fabricate L-PBF processed Mg<sub>2</sub>Si and the conventional sintering temperature of 1173 K was found to be a better limiting criterion than the melting point to prevent excessive balling and Mg vaporization. The fluidic flow velocity and its effect on the melt pool dynamics were observed experimentally. The microstructural variations in such materials are known to affect their thermoelectric performance, and the high cooling rate during the solidification in the L-PBF process favors dendritic growth, which differs from the conventionally fabricated samples possessing equiaxed grains. The microstructure evolution from the rapid solidification of the melt pool was predicted using the phase field analysis considering the effects of perturbation and the strength of anisotropy. A computational domain was simulated with an initial nucleation site of diameter 0.35 µm, and the directional dendritic growth patterns for different laser power and scan rates were obtained and analyzed. A comparable interdendritic spacing between the simulated primary dendritic arms (0.46 µm) and that measured within the L-PBF processed sample (0.57 µm) as seen under a Scanning Electron Microscope (SEM) is obtained, indicating the model’s efficacy in simulating the possible growth mechanism. The phase evolution of the L-PBF processed Mg<sub>2</sub>Si component with the implication on its thermoelectric performance and the challenges in its fabrication are discussed.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"59 ","pages":"Pages 170-185"},"PeriodicalIF":4.6,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143760082","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"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 : 2025-03-29DOI: 10.1016/j.cirpj.2025.03.003
Min Zeng , Miao Feng , J.R.R. Mayer , Elie Bitar-Nehme , Xuan Truong Duong
The volumetric accuracy of machine tools is important to both machine tool manufacturers and users. Predicting volumetric errors (VEs) is a pre-requisite for their compensation yielding increased dimensional quality of machined parts. However, predicting VEs in five-axis machine tools is challenging due to the complexity of error sources and their associated physics-based model. Machine learning (ML) is used to predict VEs under no load and stable thermal conditions. Data is acquired using a scale and master ball artefact (SAMBA) and on-machine touch probing. A general process for determining the minimum number of balls required to generate data to satisfactorily train an ML model is proposed. The VEs prediction is verified using synthetic data for inter-axis and some intra-axis geometric errors, and then validated using only experimental data. Different datasets based on decreasing number of balls are tested to train either a Neural Networks (NN) or an eXtreme Gradient Boosting (XGBoost) algorithm to compare their performances. The results show that, both NN and XGBoost are effective to predict VEs of a five-axis machine tool with wCBXfZY(S)t topology regardless of the geometric error parameter values. By using only experimental data of twenty balls to train the models, XGBoost outperforms NN in all four error metrics and processing time. A time efficient scheme was tested whereby only two master balls plus one scale bar dataset and an additional master ball (when only the spindle rotates) were used for training NN.
{"title":"Machine learning models for predicting volumetric errors based on scale and master balls artefact probing data","authors":"Min Zeng , Miao Feng , J.R.R. Mayer , Elie Bitar-Nehme , Xuan Truong Duong","doi":"10.1016/j.cirpj.2025.03.003","DOIUrl":"10.1016/j.cirpj.2025.03.003","url":null,"abstract":"<div><div>The volumetric accuracy of machine tools is important to both machine tool manufacturers and users. Predicting volumetric errors (VEs) is a pre-requisite for their compensation yielding increased dimensional quality of machined parts. However, predicting VEs in five-axis machine tools is challenging due to the complexity of error sources and their associated physics-based model. Machine learning (ML) is used to predict VEs under no load and stable thermal conditions. Data is acquired using a scale and master ball artefact (SAMBA) and on-machine touch probing. A general process for determining the minimum number of balls required to generate data to satisfactorily train an ML model is proposed. The VEs prediction is verified using synthetic data for inter-axis and some intra-axis geometric errors, and then validated using only experimental data. Different datasets based on decreasing number of balls are tested to train either a Neural Networks (NN) or an eXtreme Gradient Boosting (XGBoost) algorithm to compare their performances. The results show that, both NN and XGBoost are effective to predict VEs of a five-axis machine tool with wCBXfZY(S)t topology regardless of the geometric error parameter values. By using only experimental data of twenty balls to train the models, XGBoost outperforms NN in all four error metrics and processing time. A time efficient scheme was tested whereby only two master balls plus one scale bar dataset and an additional master ball (when only the spindle rotates) were used for training NN.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"59 ","pages":"Pages 135-157"},"PeriodicalIF":4.6,"publicationDate":"2025-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143725536","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-03-27DOI: 10.1016/j.cirpj.2025.03.007
Angela Daniela La Rosa , Ingrid Åsen , Giuseppe Ingarao , Livan Fratini
This study aims to assess the environmental impact of manufacturing ready-to-use low-alloy steel pup joints used in drilling in the oil and gas sector. The company uses low alloy steel (AISI 4145H) produced from recycled scrap via the electric arc furnace (EAF) route. The Life Cycle Assessment (LCA) is used for the environmental analysis. Foreground data at plant sites are collected from the CNC machining company in Norway and the production of steel in central Europe. Background data, such as the transportation and electricity origin, are taken from Ecoinvent 3.8. database and from literature. The system boundary of the project is gate-to-gate (from scrap to the pup joint production) and included unit processes are EAF steel production, hot rolling, quenching and tempering, CNC drilling and CNC turning. LCA results show a high contribution to the environmental impacts due to non-renewable electricity sources and materials transport among different companies in central Europe, with the final destination in Norway. Changing the source of electricity for the entire production line would generate environmental benefits. The Global Warming Potential calculated for the scenario of producing the pup joint entirely in Norway, where the electricity grid is based on hydropower (>90 %), was 215CO2eq versus 466 CO2eq for the current production line, mostly conducted in Europe with fossil fuel as main energy source. An ideal scenario can be suggested, namely the creation of an industrial park in Norway, in order to remove the transport and use renewable energy. But, more realistically, the potential limitations of the proposed solution (e.g., infrastructure costs, production capacity in Norway) should be discussed to provide a balanced view of its feasibility.
{"title":"Life Cycle Assessment of a steel component produced from electric arc furnace","authors":"Angela Daniela La Rosa , Ingrid Åsen , Giuseppe Ingarao , Livan Fratini","doi":"10.1016/j.cirpj.2025.03.007","DOIUrl":"10.1016/j.cirpj.2025.03.007","url":null,"abstract":"<div><div>This study aims to assess the environmental impact of manufacturing ready-to-use low-alloy steel pup joints used in drilling in the oil and gas sector. The company uses low alloy steel (AISI 4145H) produced from recycled scrap via the electric arc furnace (EAF) route. The Life Cycle Assessment (LCA) is used for the environmental analysis. Foreground data at plant sites are collected from the CNC machining company in Norway and the production of steel in central Europe. Background data, such as the transportation and electricity origin, are taken from Ecoinvent 3.8. database and from literature. The system boundary of the project is gate-to-gate (from scrap to the pup joint production) and included unit processes are EAF steel production, hot rolling, quenching and tempering, CNC drilling and CNC turning. LCA results show a high contribution to the environmental impacts due to non-renewable electricity sources and materials transport among different companies in central Europe, with the final destination in Norway. Changing the source of electricity for the entire production line would generate environmental benefits. The Global Warming Potential calculated for the scenario of producing the pup joint entirely in Norway, where the electricity grid is based on hydropower (>90 %), was 215CO2eq versus 466 CO2eq for the current production line, mostly conducted in Europe with fossil fuel as main energy source. An ideal scenario can be suggested, namely the creation of an industrial park in Norway, in order to remove the transport and use renewable energy. But, more realistically, the potential limitations of the proposed solution (e.g., infrastructure costs, production capacity in Norway) should be discussed to provide a balanced view of its feasibility.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"59 ","pages":"Pages 127-134"},"PeriodicalIF":4.6,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143714287","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Achieving ultra-high precision in manufacturing relies on accurate measurement systems, especially for geometries like cylindricity, which are fundamental components for precision engineering. However, current commercial cylindricity measuring machines struggle to provide the required ultra-high precision or comprehensive error analysis. This work develops an ultra-high precision cylindricity measuring machine (NanoCyl) for cylindricity profile extraction and accurate defect assessment with nanometre uncertainty. The NanoCyl incorporate the dissociated metrology structure and strict adherence to the Abbe principle, ensuring unparalleled accuracy by minimising external and internal disturbances. With in-situ calibration of capacitive probes and advanced data processing, the NanoCyl maintains traceability to the SI metre to ensure the high-precision performance. Error separation techniques (EST) are integrated into the NanoCyl to further eliminate the machine axis errors and optimise the measurement uncertainty. The NanoCyl can evaluate the three main components of cylindricity, as defined by ISO 12180–1: cross-section deviations through EST, median line deviations from harmonic signal analysis, and radial deviations using synchronised measurements from opposite probes. Experimental validation demonstrates the NanoCyl’s capability to achieve a standard measurement uncertainty within a few tens of nanometres. These findings highlight its potential for significantly improving the accuracy of cylindricity measurements, ensuring better quality control in high-precision manufacturing.
{"title":"Advanced ultra-high precision system (NanoCyl) for accurate cylindricity measurements","authors":"Rim Bennoune , Gengxiang Chen , Saint-Clair Toguem Tagne , Alain Vissiere , Mohamed Damak , Charyar Mehdi-Souzani , Nabil Anwer , René Mayer , Hichem Nouira","doi":"10.1016/j.cirpj.2025.03.005","DOIUrl":"10.1016/j.cirpj.2025.03.005","url":null,"abstract":"<div><div>Achieving ultra-high precision in manufacturing relies on accurate measurement systems, especially for geometries like cylindricity, which are fundamental components for precision engineering. However, current commercial cylindricity measuring machines struggle to provide the required ultra-high precision or comprehensive error analysis. This work develops an ultra-high precision cylindricity measuring machine (NanoCyl) for cylindricity profile extraction and accurate defect assessment with nanometre uncertainty. The NanoCyl incorporate the dissociated metrology structure and strict adherence to the Abbe principle, ensuring unparalleled accuracy by minimising external and internal disturbances. With in-situ calibration of capacitive probes and advanced data processing, the NanoCyl maintains traceability to the SI metre to ensure the high-precision performance. Error separation techniques (EST) are integrated into the NanoCyl to further eliminate the machine axis errors and optimise the measurement uncertainty. The NanoCyl can evaluate the three main components of cylindricity, as defined by ISO 12180–1: cross-section deviations through EST, median line deviations from harmonic signal analysis, and radial deviations using synchronised measurements from opposite probes. Experimental validation demonstrates the NanoCyl’s capability to achieve a standard measurement uncertainty within a few tens of nanometres. These findings highlight its potential for significantly improving the accuracy of cylindricity measurements, ensuring better quality control in high-precision manufacturing.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"59 ","pages":"Pages 118-126"},"PeriodicalIF":4.6,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143697627","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In electrical discharge machining (EDM), the concentration of discharge debris in the machining gap will affect the discharge stability, thereby determining the surface quality of the machining. As a commonly used special machining method, discharge milling often encounters the problem of residual debris in the discharge gap during the machining process, resulting in poor machining results. In order to improve the machining efficiency and surface quality of discharge milling, this study proposes magnetic field control for discharge milling. Firstly, establish a discharge milling model and discuss the changes in the flow direction and speed of the working fluid in the bottom gap and around the electrode caused by changes in the flushing direction, while keeping the electrode feed direction unchanged. And it is stipulated that the flushing direction is the same as the electrode feed direction (same direction flushing machining), and the flushing direction is the reverse as the electrode feed direction (reverse direction flushing machining). The simulation found that there is a phenomenon of Flow around circular cylinder (FACC) around the electrode, which has adverse effects on machining. By changing the flushing direction, flushing speed, and magnetic field strength, the number of debris trapped in the machining gap was compared. The results showed that reverse flushing machining is more conducive to the discharge of debris from the machining gap, and increasing the flushing speed and magnetic field strength can accelerate the discharge of debris in the machining gap. Subsequently, a verification experiment was conducted, and the experimental results showed that compared with the same direction flushing machining, the material removal rate of the reverse direction flushing machining increased from 0.93 μg/s to 2.42 μg/s, an increase of 160.22 %. The surface roughness decreased from 4.79 µm to 2.91 µm, a decrease of 39.25 %. After applying a 200mT Halbach array magnetic field control, the material removal rate increased from 2.8 μg/s to 3.67 μg/s, an increase of 31.07 %. The surface roughness decreased from 2.58 µm to 2.21 µm, a decrease of 14.34 %.
{"title":"The influence of magnetic field controlled electrical discharge milling on the surface quality of grooves","authors":"Zhiwei Qiu, Jiajing Tang, Zhengkai Li, Mulong Yin, Weiye Peng","doi":"10.1016/j.cirpj.2025.03.006","DOIUrl":"10.1016/j.cirpj.2025.03.006","url":null,"abstract":"<div><div>In electrical discharge machining (EDM), the concentration of discharge debris in the machining gap will affect the discharge stability, thereby determining the surface quality of the machining. As a commonly used special machining method, discharge milling often encounters the problem of residual debris in the discharge gap during the machining process, resulting in poor machining results. In order to improve the machining efficiency and surface quality of discharge milling, this study proposes magnetic field control for discharge milling. Firstly, establish a discharge milling model and discuss the changes in the flow direction and speed of the working fluid in the bottom gap and around the electrode caused by changes in the flushing direction, while keeping the electrode feed direction unchanged. And it is stipulated that the flushing direction is the same as the electrode feed direction (same direction flushing machining), and the flushing direction is the reverse as the electrode feed direction (reverse direction flushing machining). The simulation found that there is a phenomenon of Flow around circular cylinder (FACC) around the electrode, which has adverse effects on machining. By changing the flushing direction, flushing speed, and magnetic field strength, the number of debris trapped in the machining gap was compared. The results showed that reverse flushing machining is more conducive to the discharge of debris from the machining gap, and increasing the flushing speed and magnetic field strength can accelerate the discharge of debris in the machining gap. Subsequently, a verification experiment was conducted, and the experimental results showed that compared with the same direction flushing machining, the material removal rate of the reverse direction flushing machining increased from 0.93 μg/s to 2.42 μg/s, an increase of 160.22 %. The surface roughness decreased from 4.79 µm to 2.91 µm, a decrease of 39.25 %. After applying a 200mT Halbach array magnetic field control, the material removal rate increased from 2.8 μg/s to 3.67 μg/s, an increase of 31.07 %. The surface roughness decreased from 2.58 µm to 2.21 µm, a decrease of 14.34 %.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"59 ","pages":"Pages 98-117"},"PeriodicalIF":4.6,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143697626","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"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 : 2025-03-20DOI: 10.1016/j.cirpj.2025.02.007
Shuanglu Duan, Jia Liu, Di Zhu
Multi-tool synchronous electrochemical machining (ECM) is an efficient and cost-effective method for manufacturing blisk channels. The uniformity of the channel allowance has a significant influence on the machining accuracy of the subsequent blade profiles, and the shape of the tube electrode in multi-tool ECM is a key factor affecting the channel allowance distribution. Proposed here is a tool design method for a variable-diameter electrode (VDE) to minimize the tip-to-root allowance difference in channel ECM. The laws governing the formation of a blisk channel under motion in multiple spatial dimensions are analyzed, and the effects of the tube electrode diameter and synthesized speed on the side gap are simulated using electric fields. A mathematical relationship among these factors is established. The tube electrode is discretized into multiple microunits, and their diameters are adjusted to control the side gap and material removal as needed for the channel width, thereby reducing the allowance difference from tip to root. The microunits are then accumulated to obtain the VDE structure. Blisk-channel ECM experiments were conducted using both the designed VDE and an equal-diameter electrode (EDE). The allowance uniformity of the blisk channel machined using the VDE was improved by 32.82 % and 33.07 %, demonstrating the feasibility and effectiveness of using the VDE in the ECM process of blisk channels. By extending the VDE to multi-tool synchronous machining of blisk channels, simultaneous ECM and manufacturing of 10 channels was achieved was significantly improved machining efficiency.
{"title":"Improved allowance uniformity in multi-tool synchronous electrochemical machining of blisk channels by designing a variable-diameter tube electrode","authors":"Shuanglu Duan, Jia Liu, Di Zhu","doi":"10.1016/j.cirpj.2025.02.007","DOIUrl":"10.1016/j.cirpj.2025.02.007","url":null,"abstract":"<div><div>Multi-tool synchronous electrochemical machining (ECM) is an efficient and cost-effective method for manufacturing blisk channels. The uniformity of the channel allowance has a significant influence on the machining accuracy of the subsequent blade profiles, and the shape of the tube electrode in multi-tool ECM is a key factor affecting the channel allowance distribution. Proposed here is a tool design method for a variable-diameter electrode (VDE) to minimize the tip-to-root allowance difference in channel ECM. The laws governing the formation of a blisk channel under motion in multiple spatial dimensions are analyzed, and the effects of the tube electrode diameter and synthesized speed on the side gap are simulated using electric fields. A mathematical relationship among these factors is established. The tube electrode is discretized into multiple microunits, and their diameters are adjusted to control the side gap and material removal as needed for the channel width, thereby reducing the allowance difference from tip to root. The microunits are then accumulated to obtain the VDE structure. Blisk-channel ECM experiments were conducted using both the designed VDE and an equal-diameter electrode (EDE). The allowance uniformity of the blisk channel machined using the VDE was improved by 32.82 % and 33.07 %, demonstrating the feasibility and effectiveness of using the VDE in the ECM process of blisk channels. By extending the VDE to multi-tool synchronous machining of blisk channels, simultaneous ECM and manufacturing of 10 channels was achieved was significantly improved machining efficiency.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"59 ","pages":"Pages 83-97"},"PeriodicalIF":4.6,"publicationDate":"2025-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687068","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
It is difficult to accurately predict the critical depth of cut and the chip flow angle (CFA) using a single method provided by catastrophe theory. To solve this problem, an experimental modeling method for catastrophe phenomena combining transfer learning and catastrophe theory is proposed. This method is successfully used for the modeling of the equilibrium surface of the CFA catastrophe. First, the canonical equilibrium surface of cusp catastrophe provided by catastrophe theory is discretized in two paths (differentiated by ), and a series of canonical equilibrium point coordinates () are obtained. Then, a neural network model simulating the canonical equilibrium surface with three input nodes () and one output node () is constructed and trained. Next, the transfer learning method is applied to freeze the model and add fully connected layers before and after it to realize the required diffeomorphism from the actual parameters to the canonical parameters. The front layers have 3 nodes () and the rear layers have 1 node (). Finally, the model with the additional layers is fine-tuned using experimental data to obtain the actual equilibrium surface simulation model for the CFA catastrophe. The test results show that the prediction accuracies of the constructed model regarding the CFA and the critical depth of cut are better than those of the models established by other methods.
{"title":"Experimental modeling of equilibrium surface for chip flow angle catastrophe based on transfer learning and catastrophe theory","authors":"Yong Wang , Liangshan Xiong , Shaonan Zhang , Baoyi Zhu","doi":"10.1016/j.cirpj.2025.03.002","DOIUrl":"10.1016/j.cirpj.2025.03.002","url":null,"abstract":"<div><div>It is difficult to accurately predict the critical depth of cut and the chip flow angle (CFA) using a single method provided by catastrophe theory. To solve this problem, an experimental modeling method for catastrophe phenomena combining transfer learning and catastrophe theory is proposed. This method is successfully used for the modeling of the equilibrium surface of the CFA catastrophe. First, the canonical equilibrium surface of cusp catastrophe provided by catastrophe theory is discretized in two paths (differentiated by <span><math><mi>d</mi></math></span>), and a series of canonical equilibrium point coordinates (<span><math><mrow><mi>u</mi><mo>,</mo><mi>v</mi><mo>,</mo><mi>x</mi></mrow></math></span>) are obtained. Then, a neural network model simulating the canonical equilibrium surface with three input nodes (<span><math><mrow><mi>u</mi><mo>,</mo><mi>v</mi><mo>,</mo><mi>d</mi></mrow></math></span>) and one output node (<span><math><mi>x</mi></math></span>) is constructed and trained. Next, the transfer learning method is applied to freeze the model and add fully connected layers before and after it to realize the required diffeomorphism from the actual parameters to the canonical parameters. The front layers have 3 nodes (<span><math><mrow><mi>f</mi><mo>,</mo><mspace></mspace><msub><mrow><mi>a</mi></mrow><mrow><mi>p</mi></mrow></msub><mo>,</mo><mi>d</mi><mo>′</mo></mrow></math></span>) and the rear layers have 1 node (<span><math><mi>φ</mi></math></span>). Finally, the model with the additional layers is fine-tuned using experimental data to obtain the actual equilibrium surface simulation model for the CFA catastrophe. The test results show that the prediction accuracies of the constructed model regarding the CFA and the critical depth of cut are better than those of the models established by other methods.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"59 ","pages":"Pages 76-82"},"PeriodicalIF":4.6,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143642923","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"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 : 2025-03-08DOI: 10.1016/j.cirpj.2025.03.001
Gang Cui, Yuanping Xu, Jin Zhou, Lei Zeng, Jiuhua Xu, Zhengcai Zhao
Active control approaches based on comb filters have been widely employed to suppress the chatter issue in milling industry. However, due to the limitations in real-time regulations and filtering accuracy induced by conventional comb filter, the automation of active control for chatter still remains to be challenging. Additionally, the current chatter controllers are generally constructed based on theoretical models, making it complex and costly. Herein, a facile yet effective milling chatter active control approach is proposed based on modified comb filter and robust hybrid sensitivity controller. The modified comb filter, which can follow the spindle speed change and accurately detect /filter out the spindle rotation frequency and frequency multiplications, is developed based on the second-order generalized integrator-frequency locked loop (SOGI-FLL) technique. Meanwhile, a robust hybrid sensitivity controller based on an empirical model is proposed. A systematic simulation is conducted to elucidate the performance of the filter and controller, with emphasis on the frequency tracking accuracy, filtering effect, and chatter frequency control effect of the SOGI-FLL. The subsequently experimental results demonstrated that chatter can be suppressed effectively upon low control voltage of actuator, which are in good accordance with the theoretical results. The work highlights the feasibility of this control method in suppressing chatter, providing a new perspective for developing automated active control strategies for chatter.
{"title":"Active milling chatter control based on a modified comb filter and robust mixed sensitivity controller","authors":"Gang Cui, Yuanping Xu, Jin Zhou, Lei Zeng, Jiuhua Xu, Zhengcai Zhao","doi":"10.1016/j.cirpj.2025.03.001","DOIUrl":"10.1016/j.cirpj.2025.03.001","url":null,"abstract":"<div><div>Active control approaches based on comb filters have been widely employed to suppress the chatter issue in milling industry. However, due to the limitations in real-time regulations and filtering accuracy induced by conventional comb filter, the automation of active control for chatter still remains to be challenging. Additionally, the current chatter controllers are generally constructed based on theoretical models, making it complex and costly. Herein, a facile yet effective milling chatter active control approach is proposed based on modified comb filter and robust hybrid sensitivity controller. The modified comb filter, which can follow the spindle speed change and accurately detect /filter out the spindle rotation frequency and frequency multiplications, is developed based on the second-order generalized integrator-frequency locked loop (SOGI-FLL) technique. Meanwhile, a robust hybrid sensitivity controller based on an empirical model is proposed. A systematic simulation is conducted to elucidate the performance of the filter and controller, with emphasis on the frequency tracking accuracy, filtering effect, and chatter frequency control effect of the SOGI-FLL. The subsequently experimental results demonstrated that chatter can be suppressed effectively upon low control voltage of actuator, which are in good accordance with the theoretical results. The work highlights the feasibility of this control method in suppressing chatter, providing a new perspective for developing automated active control strategies for chatter.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"59 ","pages":"Pages 65-75"},"PeriodicalIF":4.6,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578884","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
扫码关注我们
求助内容：
应助结果提醒方式：
京公网安备 11010802042870号