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Manufacture process of Ti/Cu composite plates via prefabricated corrugated hot rolling and differential-temperature rolling 预制波纹热轧和温差轧制制备Ti/Cu复合板工艺
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-02-04 DOI: 10.1016/j.cirpj.2026.01.011
Peng Zhang , Tianfeng Wu , Zhongkai Ren , Hao Zhao , Wenwen Liu
This study used the TA1 interface prefabricated corrugated hot-rolling combined with differential temperature rolling (PCHR + DTR) process to fabricate Ti/Cu composite plates with high interfacial strength while maintaining a flat plate shape. The influence of reduction rates on the mechanical properties, microstructure, interfacial bonding, and elemental diffusion of the Ti/Cu composite plates prepared by the PCHR+DTR process was systematically investigated through mechanics performance tests and microstructural characterization. A rolling molecular dynamics model of the Ti/Cu composite plate was established to elucidate the effect of the reduction rates on diffusion behavior and formation of compound mechanisms.The results indicate that the shear strength of the composite plates prepared by this process is higher at the troughs than at the peaks and exceeds the shear performance of composite plates fabricated using the hot flat rolling + DTR process.With increasing reduction rate, the shear strength initially increased and then decreased. At an reduction rate of 50 %, the shear strength at the peak and trough reached 122.25 MPa and 166.54 MPa, respectively. Meanwhile, both tensile strength and yield strength increased with raising reduction rates, while elongation decreased due to pronounced work hardening. At an reduction rate of 60 %, the tensile strength and yield strength reached their maximum values, which were 265.45 MPa and 452.16 MPa, respectively, with a corresponding elongation minimum of 16 %. Moreover, microscopic results illustrate that grain refinement and elongation occur on both the titanium and copper sides, with more intense grain deformation observed near the interface. This is due to the rupture of the hard and brittle layers on both sides under pressure and friction, allowing fresh copper metal to infiltrate the small cracks on the titanium side, which is benefit for bonding of heterogeneous materials and grains deformation. Meanwhile,the materials on both sides of the interface are in direct contact. Compared with the substrate, the grains are subjected to greater normal stress and shear stress.At the reduction rate of 50 %, the bonding performance of the composite plate is the best, and the copper metal residue most on the titanium side at the shear fracture.
Under the influences of the rolling force and the corrugated structure, R-Cube and Copper textures are found on the copper side both at the peaks and troughs, while basal tilting textures are observed on the titanium side. At the reduction rate of 55 %, the atomic diffusion is the greatest, and the slope of the mean square displacement curve is the largest. Furthermore, atomic potential energy distribution results show no significant compound layer formation at the interface.’
本研究采用TA1界面预制波纹热轧结合差温轧制(PCHR + DTR)工艺制备出界面强度高且保持板形平整的Ti/Cu复合板。通过力学性能测试和显微组织表征,系统研究了还原速率对PCHR+DTR工艺制备的Ti/Cu复合材料的力学性能、微观结构、界面结合和元素扩散的影响。建立了Ti/Cu复合材料板的滚动分子动力学模型,阐明了还原速率对扩散行为和化合物形成机理的影响。结果表明:该工艺制备的复合材料的抗剪强度在波谷处高于波峰处,超过了热轧+ DTR工艺制备的复合材料板的抗剪性能;随着折减率的增加,抗剪强度先增大后减小。当还原率为50 %时,峰值和低谷处的抗剪强度分别达到122.25 MPa和166.54 MPa。同时,拉伸强度和屈服强度随压下率的提高而提高,而延伸率因加工硬化而降低。当还原率为60 %时,拉伸强度和屈服强度分别达到最大值265.45 MPa和452.16 MPa,延伸率最小值为16 %。此外,微观结果表明,在钛侧和铜侧均发生了晶粒细化和伸长,在界面附近观察到更强烈的晶粒变形。这是由于两侧的硬脆层在压力和摩擦作用下破裂,使新鲜的铜金属渗透到钛侧的小裂纹中,有利于异质材料的结合和晶粒变形。同时,界面两侧的材料直接接触。与基体相比,晶粒承受更大的法向应力和剪切应力。当还原率为50% %时,复合板的粘结性能最好,剪切断口处铜金属残留在钛侧最多。在轧制力和波纹结构的影响下,铜侧波峰和波谷处均出现R-Cube和Copper织构,而钛侧则出现基底倾斜织构。还原率为55 %时,原子扩散最大,均方位移曲线斜率最大。此外,原子势能分布结果表明,在界面处没有形成明显的复合层。
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引用次数: 0
Metallurgical, mechanical, and tribological characteristics and process-structure-property relationships in the additive manufacturing of AA2024/ZrO2 nanocomposites via friction surfacing 摩擦表面增材制造AA2024/ZrO2纳米复合材料的冶金、机械和摩擦学特性及工艺-结构-性能关系
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-01-31 DOI: 10.1016/j.cirpj.2026.01.002
Milad Abbasi Nahr, Seyyed Ehsan Mirsalehi, Ali Sheikholeslami
Friction surfacing (FS) is a solid-state additive manufacturing technique that utilizes high-temperature plastic deformation to create dense, fine-grained multilayer structures, thereby avoiding melting and minimizing associated defects. This process was employed to deposit AA2024/2.12 wt% ZrO2 nanocomposite multilayers on an AA2024 substrate. Subsequently, both deposited composite and non-composite samples were prepared for comparative analysis. This study systematically investigated the influence of key process parameters-consumable rod rotational speeds (600–1200 rpm), feeding rates (30‑45 mm/min), and travel speeds (70–85 mm/min)-on heat input and, consequently, microstructure refinement. Comprehensive material characterization was performed using OM, XRD, and SEM/EDS for macro- and microstructural analysis, alongside hardness and wear property assessments. Results demonstrated the successful fabrication of defect-free AA2024/ZrO2 nanocomposites exhibiting well-bonded layers, fragmented intermetallic compounds, and a uniform distribution of ZrO2. Grain size analysis revealed an average range of 2–10 μm, with reductions spanning 60.6–87.06 % across 14 manufactured samples. Enhanced hardness and wear resistance were observed in FS composites compared to non-composites, with variations in hardness across-section layers attributed to grain size evolution and precipitate dissolution. Increasing the rotational speed from 600 to 1200 rpm resulted in the deposition of wider (6 mm) and thicker (2.8 mm) layers. The optimal microstructure, achieved at a rotational speed of 1000 rpm, a feed rate of 40 mm/min, and a travel speed of 80 mm/min, featured a remarkably fine grain size of 2.91 ± 1.2 μm (an 87.06 % reduction), a hardness of 111.9 ± 9.11 HV, and a wear rate of 6.3 × 10−3 mg/N·m.
摩擦表面(FS)是一种固态增材制造技术,它利用高温塑性变形来创建致密、细粒度的多层结构,从而避免熔化并最大限度地减少相关缺陷。采用该工艺在AA2024衬底上沉积了AA2024/2.12 wt% ZrO2纳米复合多层材料。随后,制备了沉积的复合材料和非复合材料样品进行对比分析。本研究系统地研究了关键工艺参数——耗材杆转速(600-1200 rpm)、进料速度(30 - 45 mm/min)和行程速度(70-85 mm/min)对热输入的影响,从而对微观结构的细化进行了研究。通过OM、XRD和SEM/EDS对材料进行宏观和微观结构分析,以及硬度和磨损性能评估。结果表明,成功制备了无缺陷的AA2024/ZrO2纳米复合材料,具有良好的键合层,碎片化的金属间化合物和均匀分布的ZrO2。晶粒尺寸分析显示,14个样品的平均降幅为2-10 μm,降幅为60.6-87.06 %。与非复合材料相比,FS复合材料的硬度和耐磨性有所提高,其硬度横截面层的变化归因于晶粒尺寸的演变和析出相的溶解。将转速从600增加到1200 rpm导致沉积更宽(6 mm)和更厚(2.8 mm)的层。最佳的微观结构,实现转速的1000 rpm,提要 40毫米/分钟,和一个旅行80 毫米/分钟的速度,出现一个非常细粒度的2.91 ± 1.2μm(87.06 %减少),硬度111.9 ± 9.11高压,和磨损率6.3 × 10−3毫克/ N·m。
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引用次数: 0
Voxel-based rapid modeling of milling material removal for machining deformation prediction using finite cell method 基于体素的铣削材料去除快速建模及有限单元法加工变形预测
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-01-27 DOI: 10.1016/j.cirpj.2025.12.017
Zixuan Wang , Bingran Li , Hui Zhang , Peiqing Ye
In the milling of thin-walled workpiece, deformation induced by cutting force is a critical factor affecting machining quality. Accurately and efficiently predicting the milling deformation caused by cutting force before machining is an essential method for deformation optimization in thin-walled workpiece machining. In this paper, we present a novel framework that integrates voxel-based modeling of material removal volume with the finite cell method (FCM) for the efficient prediction of machining deformation. This method leverages the voxel model's ordered data storage characteristics for efficient calculation of cutter-workpiece engagement (CWE) and instantaneous cutting forces, while enabling fast stiffness matrix updates without re-meshing. This approach significantly enhances the computational efficiency and accuracy of deformation prediction based on FCM and the voxel model, while simultaneously overcoming the mesh generation challenges inherent in traditional finite element method. Finally, both simulation and physical milling experiments on thin-walled parts were conducted to verify the significant improvement in computational efficiency over traditional algorithms and the accuracy in predicting cutting-force-induced deformation, demonstrating great potential for engineering applications.
在薄壁工件的铣削加工中,切削力引起的变形是影响加工质量的关键因素。在加工前准确、高效地预测切削力引起的铣削变形是薄壁工件加工变形优化的重要方法。在本文中,我们提出了一种新的框架,该框架将基于体素的材料去除体积建模与有限单元法(FCM)相结合,以有效地预测加工变形。该方法利用体素模型的有序数据存储特性,有效计算刀具-工件啮合(CWE)和瞬时切削力,同时实现快速刚度矩阵更新,无需重新网格划分。该方法显著提高了基于FCM和体素模型的变形预测的计算效率和精度,同时克服了传统有限元法在网格生成方面存在的问题。最后,对薄壁零件进行了仿真和物理铣削实验,验证了该算法在计算效率和预测切削力引起的变形方面比传统算法有显著提高,显示了巨大的工程应用潜力。
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引用次数: 0
Nozzle clogging during extrusion based additive manufacturing of polymer matrix composites—A numerical simulation insight into the process 聚合物基复合材料挤压增材制造过程中的喷嘴堵塞——对该过程的数值模拟
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-01-26 DOI: 10.1016/j.cirpj.2026.01.009
Rajat Mishra , Swasti Chakrabarty , Amit Arora
Enhancing properties of composite materials through aligned reinforcements in an extrusion-based additive manufacturing (AM) process, is a critical objective in engineering applications. The extrusion process involves study of complex multiphase flow to determine the directionality of the reinforcement. Advanced numerical techniques are to be deployed to study the interplay of various forces and process parameters in the process. In this study, we use coupled Computational Fluid Dynamics (CFD) and Discrete Element Method (DEM) numerical techniques to investigate the flow of a graphite-reinforced PVA polymer matrix through a nozzle, a process not easily achievable through experimental means. The drag force, pressure gradient force, and virtual mass force are found significant based on a comprehensive analysis of simulation and experimental data. Non-linear regression analysis is performed to quantify the impact of these forces on reinforcement alignment. The orientation angle of reinforcements is chosen as the output parameter, with input parameters comprising nozzle outlet diameter, reinforcement aspect ratio, volume flow rate, polymer viscosity, and reinforcement concentration. Additionally, the nozzle clogging during printing is studied using the developed model. Nozzle rotation is proposed as an effective method to mitigate clogging, further enhancing the efficiency of the reinforcement alignment process. This research advances our understanding of composite material printing and offers practical solution for optimizing the alignment of reinforcements in polymer matrices, paving the way for developing high-performance composite materials with tailored properties using extrusion based AM processes.
在基于挤压的增材制造(AM)工艺中,通过对齐增强来增强复合材料的性能是工程应用中的一个关键目标。挤压过程涉及复杂多相流的研究,以确定强化的方向性。采用先进的数值技术来研究过程中各种力和工艺参数的相互作用。在这项研究中,我们使用耦合计算流体力学(CFD)和离散元方法(DEM)数值技术来研究石墨增强PVA聚合物基体通过喷嘴的流动,这一过程不容易通过实验手段实现。通过对仿真和实验数据的综合分析,发现了阻力、压力梯度力和虚拟质量力的显著性。进行非线性回归分析,以量化这些力对钢筋对齐的影响。输出参数选择增强剂取向角,输入参数为喷嘴出口直径、增强剂长径比、体积流量、聚合物粘度和增强剂浓度。此外,利用所建立的模型对打印过程中的喷嘴堵塞进行了研究。提出了喷嘴旋转是一种有效的缓解堵塞的方法,进一步提高了补强过程的效率。这项研究提高了我们对复合材料打印的理解,并为优化聚合物基体中增强材料的排列提供了实用的解决方案,为使用基于挤压的增材制造工艺开发具有定制性能的高性能复合材料铺平了道路。
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引用次数: 0
Mechanical strength of 3D-printed lattices under different environmental conditions 不同环境条件下3d打印格子的机械强度
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-01-26 DOI: 10.1016/j.cirpj.2026.01.004
Mohammad Reza Khosravani , Amirmahdi Abdollahi , Hadi Sadeghian , Majid R. Ayatollahi , Tamara Reinicke
In this study Additive Manufacturing (AM, i.e., 3D printing) has been used for fabrication of lattices with three different geometries: honeycomb, fourfold, and re-entrant. The specimens were fabricated based on the material extrusion technique, using Polyethylene Terephthalate Glycol (PETG) filament, which was reinforced with short carbon fiber additives. Since 3D-printed components might be subjected to various environmental conditions during their service life, here some of the test coupons were artificially aged (-5 to 40 °C) to determine effects of this thermal aging on their mechanical behavior. Based on a series of mechanical tests on the aged and unaged specimens, the deformation and energy absorption capabilities of the specimens were compared. Parallel to the experiments, two dimensional Finite Element Model (FEM) was developed to evaluate the mechanical performance and investigate the stress distribution and plastic deformation of the examined lattice structures. Moreover, Fractography analysis was conducted using Scanning Electron Microscope (SEM) images. The experimental findings indicate that energy absorption until damage initiation and energy absorption until the densification have been increased in almost all specimens due to the conducted thermal aging. In addition, SEM images indicate that during the loading process a higher amounts of energy was dissipated in the aged re-entrant lattices structure, compared to unaged test coupons. The documented results can be used for design and fabrication of thermal-stable 3D-printed composite parts.
在这项研究中,增材制造(AM,即3D打印)已被用于制造三种不同几何形状的晶格:蜂窝状、四倍状和重入式。基于材料挤压技术,采用聚对苯二甲酸乙二醇酯(PETG)长丝,添加短碳纤维添加剂进行增强。由于3d打印部件在其使用寿命期间可能会受到各种环境条件的影响,因此在这里,一些测试片被人工老化(-5至40°C),以确定这种热老化对其机械行为的影响。通过对时效和未时效试件进行一系列力学试验,比较了试件的变形和吸能能力。在实验的基础上,建立了二维有限元模型,对晶格结构的力学性能进行了评价,并对晶格结构的应力分布和塑性变形进行了研究。此外,还利用扫描电镜(SEM)图像进行了断口分析。实验结果表明,几乎所有试样在传导热时效作用下,损伤起始前的能量吸收和致密化前的能量吸收都有所增加。此外,SEM图像表明,在加载过程中,与未老化的试验片相比,老化的重入晶格结构中耗散的能量更高。记录的结果可用于设计和制造热稳定的3d打印复合材料部件。
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引用次数: 0
Suppression of chatter in thin-walled component milling through shear thickening fluids 剪切增稠液对薄壁零件铣削颤振的抑制
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-01-24 DOI: 10.1016/j.cirpj.2026.01.007
Shuqi Wang , Shengjie Zhou , Dongliang Gao , Xiaoqiu Xu , Chunlei He
In the milling of thin-walled components, the inherently low stiffness of these structures makes the occurrence of chatter a critical issue that significantly limits machining accuracy and productivity. To address this challenge, this study proposes a novel approach for chatter suppression based on the shear thickening effect. Two representative types of shear thickening fluids (STFs)—silicon dioxide-polyethylene glycol (SiO₂-PEG) and cornstarch-water—are experimentally investigated. Initially, the modal parameters of thin-walled workpieces, both with and without the application of STFs, are determined separately through experimental modal analysis. Subsequently, a nonlinear milling dynamics model is formulated using Hamilton’s principle, incorporating the kinetic energy, strain energy, boundary potential energy, and strain potential energy of the system, as well as the rheological and mechanical properties of the STF. The stability lobe diagram is then computed using the full-discretization method to analyze the dynamic stability of the system. To further validate the vibration suppression effectiveness of the STFs, milling vibration tests are conducted using different types and mass fractions of the fluid. The results indicate that the application of STF significantly reduces the natural frequency and increases the damping ratio of the cutting system, thereby achieving a notable suppression of milling vibrations and improving the milling surface roughness.
在薄壁零件的铣削加工中,这些结构固有的低刚度使得颤振的发生成为一个严重限制加工精度和生产率的关键问题。为了解决这一挑战,本研究提出了一种基于剪切增厚效应的颤振抑制新方法。对两种具有代表性的剪切增稠流体(STFs)——二氧化硅-聚乙二醇(SiO₂-PEG)和玉米淀粉-水进行了实验研究。首先,通过试验模态分析,分别确定了施加stf和不施加stf时薄壁工件的模态参数。随后,利用Hamilton原理建立了非线性铣削动力学模型,将系统的动能、应变能、边界势能、应变势能以及STF的流变和力学特性结合起来。利用全离散化方法计算了系统的稳定性叶瓣图,分析了系统的动态稳定性。为了进一步验证STFs的抑振效果,使用不同类型和质量分数的流体进行了磨铣振动试验。结果表明,STF的应用显著降低了切削系统的固有频率,增加了切削系统的阻尼比,从而显著抑制了铣削振动,提高了铣削表面粗糙度。
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引用次数: 0
Surface quality classification in burnished aluminum alloys based on nonlinear dynamic characteristics and machine learning 基于非线性动态特性和机器学习的抛光铝合金表面质量分类
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-01-19 DOI: 10.1016/j.cirpj.2026.01.005
Cong Ding , Shiqing Feng , Xing Liu , Michael G. Bryant , Yan Zhao , Jianfei Han , Zhongyu Piao
Active control of surface quality requires insight into both processing parameters and the nonlinear dynamic behavior of machining systems. However, existing studies mainly focus on microscopic surface attributes and often overlook their relationship with system-level nonlinear dynamics, limiting both predictive accuracy and mechanistic understanding. To address this gap, this study investigates the surface burnishing process (SBP) by integrating process parameters, vibration-based nonlinear dynamic analysis, and machine learning. A quantitative intrinsic mode function (IMF) screening method based on ensemble empirical mode decomposition (EEMD) and power spectral density (PSD) was proposed to enhance vibration signal denoising and feature reliability. Chaotic behavior of the SBP system was confirmed by a positive maximum Lyapunov exponent (λmax>0), and a set of recurrence quantification analysis (RQA) parameters was extracted. Three feature scenarios, SBP parameters with positional encoding, chaotic features, and their combination, were evaluated for classifying surface roughness and hardness. Results showed that surface roughness was predominantly governed by burnishing parameters, whereas hardness prediction benefited more from RQA parameters reflecting the surface deformation stability. The findings clarify the distinct roles of deterministic and dynamic factors in surface-quality formation and provide a flexible, physically interpretable framework for data-driven surface-quality prediction and adaptive manufacturing applications.
表面质量的主动控制需要深入了解加工参数和加工系统的非线性动态行为。然而,现有的研究主要集中在微观表面属性,往往忽略了它们与系统级非线性动力学的关系,限制了预测的准确性和机理的理解。为了解决这一差距,本研究通过整合工艺参数,基于振动的非线性动态分析和机器学习来研究表面抛光过程(SBP)。为了提高振动信号去噪和特征可靠性,提出了一种基于集合经验模态分解(EEMD)和功率谱密度(PSD)的本征模态函数(IMF)定量筛选方法。通过正最大Lyapunov指数(λmax>0)证实了SBP系统的混沌行为,并提取了一组递归量化分析(RQA)参数。对具有位置编码的SBP参数、混沌特征及其组合三种特征场景进行了评价,用于表面粗糙度和硬度的分类。结果表明,表面粗糙度主要受抛光参数的影响,而硬度预测更多地受益于反映表面变形稳定性的RQA参数。研究结果阐明了确定性因素和动态因素在表面质量形成中的不同作用,并为数据驱动的表面质量预测和自适应制造应用提供了一个灵活的、物理可解释的框架。
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引用次数: 0
Methodology to quantify the recyclability of design alternatives for highly integrated technical products applied to lithium-ion batteries 量化应用于锂离子电池的高度集成技术产品设计替代方案的可回收性的方法
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-01-17 DOI: 10.1016/j.cirpj.2026.01.003
S. Hansen , F. Vysoudil , A. Dlugosch , J. Riech , M. Mennenga , S. Blömeke , T. Vietor , C. Herrmann
High manufacturability and usability demands lead to an increasing complexity of technical products, which in turn reduces their recyclability. However, to assess the consequences a dedicated Design for Recycling would have in End of Life is challenging due to the complex dependencies between product design and recycling systems which are particularly difficult to estimate in early-stage product development. It is especially the economic benefits, however, that need to be made transparent to reach a widespread application of Design for Recycling in industry. Therefore, this paper presents a methodology to assess economic aspects of a design-dependent End of Life behavior of a product with minimal initial information, which reflects the constraints typical for Product Development Processes. It offers a structured analytical evaluation of design impacts on costs and revenues as well as on the recycling progress that the single steps throughout the End-of-Life process chain would entail. The methodology is exemplarily applied to two electric bike batteries that exhibit significant differences in terms of their recyclability. Results show that these differences are clearly identifiable and the advantages of the more recycling-friendly design can be demonstrated.
高可制造性和可用性要求导致技术产品的复杂性增加,这反过来又降低了它们的可回收性。然而,由于产品设计和回收系统之间的复杂依赖关系,在产品开发的早期阶段特别难以估计,因此评估专门的回收设计在生命终止时所产生的后果是具有挑战性的。然而,要使回收设计在工业上得到广泛应用,经济效益尤其需要透明。因此,本文提出了一种方法,以最小的初始信息来评估产品的设计依赖的寿命终止行为的经济方面,这反映了产品开发过程的典型约束。它提供了对设计对成本和收入的影响的结构化分析评估,以及在整个生命周期结束过程链中的单个步骤所需要的回收进度。该方法以两种在可回收性方面表现出显著差异的电动自行车电池为例。结果表明,这些差异是清晰可识别的,并且可以证明更环保设计的优势。
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引用次数: 0
Physics-based feature enhancement method and physics constraint Transformer model for multi-step tool wear and RUL prediction 基于物理的特征增强方法和物理约束Transformer模型用于多步刀具磨损和RUL预测
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-01-14 DOI: 10.1016/j.cirpj.2026.01.001
Shanglei Jiang , Haoyuan Zhang , Zhengmao Chen , Yuwen Sun , Xuexia Liu
In intelligent manufacturing, tool wear monitoring (TWM) and remaining useful life (RUL) prediction are crucial for improving production quality and efficiency. However, achieving accurate and reliable multi-step (long-term) predictions remains a substantial challenge. This research proposes a feature enhancement method and constructs a Transformer model that embeds hard-soft physics constraints for multi-step wear and RUL prediction. Firstly, the fast adaptive Brownian bridge aggregation algorithm (fABBA) is employed to extract the features from multiscale signals during machining, alleviating the reliance on domain knowledge inherent in traditional feature engineering to some extent. On this basis, a physics-based feature enhancement method is proposed to improve the model’s generalization. Secondly, a Transformer model based on multi-head self-attention and cross-attention mechanisms is constructed for multi-step tool wear and RUL prediction. Meanwhile, a hard-soft physical constraint embedding module is designed to ensure that the model's output has a certain degree of physical interpretability. Finally, the PHM2010 and self-constructed datasets are employed to verify the effectiveness of the proposed method. Shapley Additive Explanations (SHAP) analysis method is used to quantitatively analyze the contribution of features to the model. The wear comparison experiments on the PHM2010 dataset, using C6 as the test set, show that the proposed model achieves RMSE values of 1.680672 ± 0.137001, 2.220760 ± 0.145516, 3.430798 ± 0.485509, and 5.106184 ± 0.690110 for 12, 24, 36 and 48 step predictions, respectively. Even for the ultra-long wear prediction, the R2 remains at 0.981760 ± 0.005227, which is better than GRU, BiGRU, BiGRU-AT, and TCN models.
在智能制造中,刀具磨损监测(TWM)和剩余使用寿命预测(RUL)对提高生产质量和效率至关重要。然而,实现准确可靠的多步骤(长期)预测仍然是一个重大挑战。本研究提出了一种特征增强方法,并构建了一个嵌入软硬物理约束的Transformer模型,用于多步磨损和RUL预测。首先,采用快速自适应布朗桥聚合算法(fABBA)从加工过程中的多尺度信号中提取特征,在一定程度上减轻了传统特征工程对领域知识的依赖;在此基础上,提出了一种基于物理的特征增强方法来提高模型的泛化能力。其次,构建了基于多头自注意和交叉注意机制的Transformer模型,用于多步刀具磨损和RUL预测。同时设计了软硬物理约束嵌入模块,保证模型输出具有一定的物理可解释性。最后,利用PHM2010和自构建数据集验证了所提方法的有效性。采用Shapley加性解释(SHAP)分析方法定量分析特征对模型的贡献。在PHM2010数据集上,以C6为测试集进行磨损对比实验,结果表明,该模型在12步、24步、36步和48步预测下的RMSE值分别为1.680672±0.137001、2.220760±0.145516、3.430798±0.485509和5.106184±0.690110。即使对于超长磨损预测,R2仍为0.981760±0.005227,优于GRU、BiGRU、BiGRU- at和TCN模型。
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引用次数: 0
Temperature field characteristics in rotary longitudinal-torsional ultrasonic machining of unidirectional carbon fiber reinforced polymer (CFRP) 单向碳纤维增强聚合物(CFRP)旋转纵扭超声加工温度场特征
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-01-07 DOI: 10.1016/j.cirpj.2025.12.019
Ziqiang Zhang , Feng Jiao , Yuanxiao Li
Enhancing the drilling quality of carbon fiber reinforced polymer (CFRP) holds significant importance for advancing its application in aerospace and other fields. The temperature during CFRP core drilling critically impacts hole quality, and incorporating ultrasonic vibration during machining can effectively reduce this temperature. Predicting workpiece temperature is vital for selecting process parameters and enhancing hole quality of CFRP core drilling. However, current research on rotary ultrasonic machining (RUM) of CFRP predominantly focuses on experimental investigations, which relatively few reports on the temperature prediction. Utilizing the benefits of longitudinal-torsional ultrasonic vibration to reduce temperature, this paper establishes a temperature prediction model for rotary longitudinal-torsional ultrasonic machining (RLTUM) of unidirectional CFRP and analyzes the temperature field characteristics. Initially, the heat source properties in the machining process are analyzed, followed by an examination of heat transfer characteristics using the heat source method. Furthermore, the surface morphology of CFRP hole wall under different machining conditions was compared. Experimental verification confirms the model’s accuracy, demonstrating its capability to predict temperature evolution and variation trends with process parameters. The peak temperature prediction errors perpendicular and parallel to the fiber direction are 7.09–12.63 % and 5.54–14.36 %, respectively. Implementing longitudinal-torsional ultrasonic vibration reduces temperature during the core drilling process. As the fiber orientation angle increases, the corresponding peak temperature decreases, and the peak temperatures for different fiber orientation angles are symmetrical. This model serves as a valuable reference for selecting process parameters to improve CFRP drilling quality.
提高碳纤维增强聚合物(CFRP)的钻孔质量对推进其在航空航天等领域的应用具有重要意义。CFRP钻芯过程中的温度对孔质量影响很大,在加工过程中加入超声振动可以有效降低该温度。预测工件温度对CFRP钻芯工艺参数的选择和提高孔质量具有重要意义。然而,目前对CFRP旋转超声加工(RUM)的研究主要集中在实验研究上,而对温度预测的研究相对较少。利用超声纵扭振动降低温度的优势,建立了单向碳纤维复合材料旋转纵扭超声加工(RLTUM)的温度预测模型,并分析了温度场特征。首先,分析了加工过程中的热源特性,然后使用热源法检查了传热特性。并对不同加工条件下CFRP孔壁的表面形貌进行了比较。实验验证了该模型的准确性,证明了该模型能够预测温度随工艺参数的变化趋势。垂直和平行于光纤方向的峰值温度预测误差分别为7.09 ~ 12.63 %和5.54 ~ 14.36 %。在钻取岩心的过程中,实施纵向-扭转超声振动可以降低温度。随着纤维取向角的增大,相应的峰值温度降低,且不同取向角的峰值温度是对称的。该模型为提高CFRP钻孔质量选择工艺参数提供了有价值的参考。
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CIRP Journal of Manufacturing Science and Technology
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