CIRP Journal of Manufacturing Science and Technology最新文献

Nanostructuring of the titanium alloy Ti-13Nb-13Zr (NanoTNZ) for osteosynthesis implants by continuous multidirectional swaging

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-02-05 DOI: 10.1016/j.cirpj.2025.01.008

Lukas Kluy , Peter Groche , Lina Klinge , Carsten Siemers , Christopher Spiegel

Musculoskeletal traumata involving damaged bones can reduce patients’ mobility and be life-threatening due to fracture-related infections. Osteosynthesis implants are increasingly vital for stabilizing fractures, especially with the growing prevalence of osteoporotic fractures in the aging population. However, advancements in manufacturing research are crucial for enhancing the biomechanical properties of these implants, improving healing outcomes, and enabling large-scale production. This study focuses on the development of a novel manufacturing process for the nanostructured titanium alloy Ti-13Nb-13Zr (NanoTNZ) using continuous multidirectional swaging (CMDS) followed by recrystallization and ageing. Various thermomechanical parameters were explored to ensure homogeneous strain and hardness distribution and fully nanostructure the alloy. Process limitations such as chevron cracks and shear bands were overcome by applying counter pressure for hydrostatic compression stress, enabling damage-free forming. Ageing of CMDS-TNZ leads to partial α''-martensite decomposition into finer structures of α_s and β phase resulting in a microstructure with substructures smaller than 100 nm. NanoTNZ exhibits a Young's modulus of 92 GPa, an ultimate tensile strength of 981 MPa, and 8 % elongation at rupture. A bone plate of NanoTNZ was manufactured to demonstrate the efficacy of this continuous thermomechanical nanostructuring technique to produce next generation osteosynthesis implants.

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引用次数: 0

Influence of cooling lubricants on mechanical load at the cutting wedge using high-speed microcinematography and an open-contra rotation tribometer

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-02-05 DOI: 10.1016/j.cirpj.2025.01.010

Berend Denkena , Gerhard Poll , Benjamin Bergmann , Florian Pape , Belal Nassef , Jan Schenzel

The use of cooling lubricant (CL) in machining influences the thermo-mechanical load of the tool and can increase both the workpiece quality and the metal removal rate. However, a targeted design of the CL supply strategy is not possible due to a lack of basic knowledge on the mechanisms of cooling lubricants. Therefore, the mechanical load on the cutting wedge is investigated in dependence of the CL-supply pressure for a cutting oil and an emulsion. It can be seen that the maximum normal stress increases with increasing CL-pressure due to a reduction in contact length. The maximum tangential stress shows a minimum for p = 45 bar and therefore a reduction in mechanical tool load when using cooling lubricants. The friction in the secondary shear zone is analysed using local coefficients of friction and an open contra-rotation tribometer. A critical contact length CL_RF,crit has been determined where a significant reduction in friction as a result of the lubrication of the chip-tool contact occurs for an increasing contact at the rake face. In order to investigate the contact conditions in the presence of CL fundamental tribometer investigations were conducted. Based on this it is shown that there is no penetration to the cutting edge near the primary shear zone using CL-supply from the rake face.

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引用次数: 0

Analysis of root residual stress and total tooth profile deviation in hobbing and investigation of optimal parameters

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-02-04 DOI: 10.1016/j.cirpj.2025.01.007

Yazhou Wang, Huike Xu, Zhiying Ou, Jianhui Liu, Gang Wang

The residual stress(RS) at tooth root from machining significantly affects bending fatigue performance of gears. Aiming at minimizing the root RS while ensuring the gear accuracy during hobbing process, the integrated method of numerical simulation, response surface, Non-dominated Sorting Genetic Algorithm-II (NSGA-II), principal component analysis, entropy weight calculation and combined weighting of game theory was adopted. Firstly, a simulation step for root RS in hobbing was proposed to obtain the incidence relation between process parameters and root RS, aiming to provide a reference for preselection process parameters in subsequent experiments. Then, the response surface experiment was designed to create regression models and analyze interaction effect of process parameters on total tooth profile deviation and root RS. Then, NSGA-II was adopted to optimize total tooth profile deviation and root RS, acquiring Pareto frontier solution set. Finally, the optimum process parameters of hobbing were determined by the method of principal component analysis, entropy weight calculation and game theory combination weighting. The research result indicates that hob speed seriously affects total tooth profile deviation and root RS. The optimal total tooth profile deviation and root RS are 10.31 µm and 131.13 MPa. The optimum hob speed, axial feed speed and radial cutting times are respectively 766.13 r/min, 1.888 mm/min and 3.58 times. The effectiveness of optimization method is verified by experiments, and the error is within 10 %. This research can effectively reduce the root RS from machining under the premise of ensuring machining accuracy, and provide a significant reference for improving the bending fatigue performance of gears.

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引用次数: 0

Real-time global smoothing and interpolation for five-axis short line segment toolpaths through G0-G1-C2 two layered fairing

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.cirpj.2024.11.006

De-Ning Song , Jing-Song Li , Zheng-Mao Jin , Jing-Hua Li , Jian-Wei Ma

Short line segment toolpaths widely used in five-axis CNC machine tools has the defects of low-order continuity, the tangential and curvature discontinuities at the corners, which result in frequent fluctuation of feedrate, thus degrading the machining quality and efficiency. Therefore, smoothing interpolation of the path becomes significant. Although the local corner smoothing methods are relative mature, the global smoothing methods can hardly be fulfilled in real time, because either the replacing of line segments by global smooth curves or the scheduling of five-axis feedrate requires time-consuming iterative or pre-processed computing. To deal with above problem, this paper proposes a real-time global smoothing and interpolation method for five-axis short line segment toolpaths. This is realized by a G0-G1-C2 two layered fairing method, containing a G0-G1 outer-layer smoothing step and a G1-C2 inner-layer smoothing step. In the outer layer, a piecewise dual B-spline with globally G1 continuity is constructed for replacing the G0 continuous line-segment toolpath. Further, in the inner layer, a FIR (Finite Impulse Response) convolving algorithm is presented for generating C2-continuous axial trajectories with bounded acceleration and jerk, according to the G1 dual-spline path. Both of the two layers are lightweight in computation, which makes the proposed global smoothing method have strong real-time capability. Verification and comparison tests demonstrate that the proposed method performs similarly with existing off-line methods in smoothing results, but performs overwhelmingly in real-time capability, and its single-step computation calls for merely about 12 % of the total interpolation period.

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引用次数: 0

Manufacturing and characterisation of highly porous metal bonded diamond grinding wheels

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.cirpj.2024.12.006

Berend Denkena, Benjamin Bergmann, Lennart Puls, Daniel Raffalt, Maren Friedrich, Kai Lübbermann

Currently, there is no economical method for producing porous metal-bonded diamond grinding wheels. The availability of such a method would allow for the combination of the advantages of a highly porous vitrified-bonded grinding wheel with the high strength of a metal-bonded grinding wheel. This work investigates two methods for the production of porous metal-bonded grinding wheels to achieve this goal. It is shown that it is possible to produce porous metal bonds for grinding tools based upon small adjustments to a FAST sintering process. This allows the production of porous metal-bonded grinding tools with existing infrastructure and known bonding systems. A model is derived for the reproducible design of porosity up to 30 % by volume based on manufacturing parameters, as well as the influence of the pore content on the mechanical properties of the bond material. Secondly, a method for evaluating the self-sharpening behaviour of grinding wheel bonds depending on the workpiece material is proposed. In grinding experiments using dense and porous metal-bonded grinding wheels, the increased self-sharpening effect for the porous bond is confirmed as well as a reduction in grinding forces. This shows the high potential of metallic porous bonds with regard to self-sharpening.

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引用次数: 0

Tool segmentation design method of hybrid optimization framework with geometric modeling-finite element-genetic algorithm

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.cirpj.2024.12.001

Tao Zhou , Hao Cui , Feilong Du , Cheng Zhang , Pengfei Tian , Lin He

The contact area between the turning tool and the chip (workpiece) experiences friction, normal composite forces, and high temperatures under severe working conditions. Optimizing the tool geometry at the contact point with the chip is crucial for enhancing the comprehensive cutting performance of the turning tool. This study proposes a tool segmentation optimization design method within a hybrid optimization framework. Initially, a three-segment parametric geometric model of the tool, comprising the rake face shape, transition zone length, and tool edge radius, is constructed. Subsequently, a two-dimensional cutting simulation model based on thermal-mechanical coupling is developed. Utilizing Python, the model inputs and data response outputs from the ABAQUS cutting simulation process are redeveloped to facilitate direct, automatic iterative optimization of the tool structure using a genetic algorithm. The study explores the impact of varying cutting thicknesses on the optimal rake face shape, revealing that increased feed rates expand the optimization potential for minimizing cutting forces. The methodology was applied to the design of a cemented carbide turning tool for H13 steel, and comprehensive cutting performance tests were conducted. The findings indicate that the optimized tool significantly reduces temperatures and strain in the shear and friction zones, diminishes plastic deformation of the chip, and cuts the cutting force by approximately 8 %. Additionally, it lowers the adhesion of workpiece material on the rake face, reduces the contact area between the tool and the chip, and improves the workpiece's surface finish. The proposed method can provide a new automatic optimization design framework for the effective upgrading of the turning tool structure of traditional difficult-to-cut materials and the efficient development of the turning tool structure of new materials.

在恶劣的工作条件下，车刀与切屑（工件）之间的接触区域会受到摩擦力、法向复合力和高温的影响。优化刀具与切屑接触点的几何形状对提高车刀的综合切削性能至关重要。本研究在混合优化框架内提出了一种刀具分段优化设计方法。首先，构建刀具的三段参数几何模型，包括前刀面形状、过渡区长度和刀刃半径。随后，开发了基于热机械耦合的二维切削仿真模型。利用 Python，重新开发了 ABAQUS 切削仿真过程中的模型输入和数据响应输出，以便使用遗传算法对刀具结构进行直接、自动的迭代优化。研究探讨了不同切削厚度对最佳耙面形状的影响，发现提高进给率可扩大优化潜力，最大限度地减少切削力。该方法被应用于 H13 钢硬质合金车刀的设计，并进行了全面的切削性能测试。结果表明，优化后的刀具能显著降低剪切区和摩擦区的温度和应变，减少切屑的塑性变形，并将切削力降低约 8%。此外，它还降低了工件材料在耙面上的附着力，减少了刀具与切屑之间的接触面积，提高了工件的表面光洁度。所提出的方法可为传统难切削材料车刀结构的有效升级和新型材料车刀结构的高效开发提供新的自动优化设计框架。

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引用次数: 0

Nonlinear periodic response analysis of mechatronic systems with friction

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.cirpj.2024.11.004

Edwin Pink , Leo Brockhuis , Nino Ceresa , Daniel Spescha , Konrad Wegener

Nonlinearities are present in many coupling components of mechanical and mechatronic systems, with the most common nonlinear coupling property being that of friction force. Transient simulation of systems with nonlinear friction can be a challenge in terms of solver robustness and calculation time. Moreover, many manufacturing processes lead to periodic forces and motions such as in milling, or repetitive pick-and-place serial production operations. In this paper, a method and application for nonlinear periodic response analysis (NPRA) of reduced-order mechatronic systems is presented, which leverages the fact that the majority of components in common mechatronic systems (e.g. machine tools) are linear. The dynamic behaviour of these components can thus be represented using a linear reduced order model (ROM). The analysis is implemented using the Harmonic Balance Method (HBM), which is then applied to the ROM of a simple, structurally compliant mechatronic system with a motion controller and profiled rail guideways. A practical case encountered in industrial settings is analysed, that being the testing of a system’s frequency response. Periodic responses to a harmonic velocity setpoint input oscillation are analysed in both time and frequency domains and comparisons then made between measurement and simulation. This comparison shows that many significant effects of nonlinear friction in ROMs of mechatronic systems can be modelled using the NPRA method and a simple friction model with a presliding regime. The combination of HBM with model order reduction (MOR) opens up a field of applications for the efficient and robust simulative analysis of periodic processes with nonlinear couplings in complicated mechatronic systems.

机械和机电一体化系统的许多耦合元件都存在非线性，其中最常见的非线性耦合特性是摩擦力。对具有非线性摩擦力的系统进行瞬态模拟，在求解器的鲁棒性和计算时间方面都是一个挑战。此外，许多制造过程都会产生周期性的力和运动，如铣削或重复性的取放式批量生产操作。本文介绍了一种用于减阶机电一体化系统非线性周期响应分析（NPRA）的方法和应用，该方法利用了常见机电一体化系统（如机床）中大多数组件都是线性的这一事实。因此，这些组件的动态行为可以用线性降阶模型（ROM）来表示。使用谐波平衡法（HBM）进行分析，然后将其应用于带有运动控制器和型轨导轨的简单、结构顺应性机电一体化系统的 ROM。分析了工业环境中遇到的一个实际案例，即系统频率响应测试。在时域和频域对谐波速度设定点输入振荡的周期响应进行分析，然后对测量和模拟进行比较。比较结果表明，机电一体化系统 ROM 中非线性摩擦的许多重要影响可以使用 NPRA 方法和具有预滑动机制的简单摩擦模型进行建模。HBM 与模型阶次缩减 (MOR) 的结合为复杂机电一体化系统中具有非线性耦合的周期性过程的高效、稳健模拟分析开辟了应用领域。

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引用次数: 0

A manufacturability analysis method for sheet metal based on rule reasoning

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.cirpj.2024.12.004

Jinfeng Liu, Mian Wu, Yu Chen, Qiukai Ji, Yang Xie

Sheet metal parts are the fundamental components for realizing the structural characteristics of aircraft, and their design efficiency and quality directly influence the cost and performance of products. Currently, many aviation enterprises rely on experiential methods to inspect the design quality of parts, leading to challenges such as inconsistent inspection specifications, low efficiency and a high likelihood of errors. To address these issues, a manufacturability analysis method for sheet metal part is proposed based on rule reasoning. Firstly, the topological information of sheet metal part is classified and combined according to geometric characteristics and its topological relationships, and the topological face set of the features is constructed. Secondly, the manufacturing feature recognition methods based on rule reasoning is proposed, and standardized information models are established based on these manufacturing features. Subsequently, the manufacturability rules are established based on the process criteria in the actual processing requirements. The attribute information contained in the design model is compared with the process rule information to identify the attributes that do not comply with the processing requirements. Finally, a manufacturability evaluation software system for aircraft sheet metal part is developed, and several typical parts containing various concave features are successfully tested.

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引用次数: 0

Insights into the fabrication of microchannels on biomedical NiTinol

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.cirpj.2024.12.003

Josenilton dos Santos Lopes , Pietro Bedule Câmara , Rahul Davis , Carlos José de Araujo , Marcio Bacci da Silva , Álisson Rocha Machado

The nickel-titanium alloy (NiTinol) exhibits shape memory and superelasticity behavior, stemming from its remarkable ability to alter the atomic bonding types and mechanical properties significantly. NiTtinol is utilized in biomedical as well as aerospace applications. However, as reported by the recent literature, achieving the desired machinability characteristics on NiTinol at macro as well as micro levels is considerably challenging. In this context, this study aims to investigate the machinability of Biomedical grade NiTinol during its micromilling with minimum quantity lubrication (MQL), primarily focusing on the tool wear evolution, wear mechanisms, surface roughness, and burr formation. In addition, the frequency spectrum of the surface roughness profile was analyzed. For this purpose, experiments were conducted comprising the fabrication of microchannels measuring 27.0 mm in length using TiAlN coated 400 µm diameter micro end mills. A cutting speed of 12.57 m/min, feed rate of 1 µm/tooth, and axial depth of cut of 40 µm were employed. The results revealed that the formation of built-up edge (BUE) served as a protective barrier for the cutting-edge of the microtools, with adhesion or attrition identified as the predominant wear mechanisms. The measured surface roughness value Ra ranged from 0.0411 ± 0.0040 µm to 0.0461 ± 0.0070 µm. The frequency spectrum of the roughness profile analysis detected that feed rate was not the primary factor. Finally, the burr height and area on the down-milling side were consistently found to be larger than those observed on the up-milling side.

镍钛合金（NiTinol）具有形状记忆和超弹性特性，这源于其显著改变原子键合类型和机械特性的能力。镍钛诺可用于生物医学和航空航天领域。然而，根据最新文献报道，要在宏观和微观层面上实现镍钛诺所需的机械加工特性具有相当大的挑战性。在此背景下，本研究旨在研究生物医学级镍钛诺在使用最小量润滑（MQL）进行微孔加工时的可加工性，主要关注刀具磨损演变、磨损机制、表面粗糙度和毛刺形成。此外，还分析了表面粗糙度曲线的频谱。为此，实验包括使用直径为 400 µm 的 TiAlN 涂层微型立铣刀制造长度为 27.0 mm 的微通道。切削速度为 12.57 米/分钟，进给速度为 1 微米/齿，轴向切削深度为 40 微米。结果表明，堆积刃（BUE）的形成对微型刀具的切削刃起到了保护作用，粘附或磨损是主要的磨损机制。测得的表面粗糙度值 Ra 在 0.0411 ± 0.0040 µm 到 0.0461 ± 0.0070 µm 之间。粗糙度轮廓的频谱分析表明，进给率不是主要因素。最后，发现下铣侧的毛刺高度和面积始终大于上铣侧的毛刺高度和面积。

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引用次数: 0

Progressive scheme via eccentric rotation of abrasive cutting edges for minimum damage machining of fibre reinforced polymer composites: Micro-mechanics and performance aspects

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.cirpj.2024.12.002

Danish Handa, V.S. Sooraj

Progressive-intermittent cutting using controlled eccentricity to the rotation of grinding wheel, referred to as “eccentric sleeve grinding”, is projected as one of the promising methodologies for minimising damages while machining Fibre Reinforced Polymer Composites (FRPs). This paper unveils the micromechanics of eccentric sleeve grinding through a detailed investigation of the progressive interaction of abrasive cutting edges with a fibre-matrix system. The theoretical model in this paper provides a comprehensive understanding of the contact/cutting behaviour of abrasive grains located on a wheel that rotates with fine eccentricity during its interaction with the matrix as well as fibres embedded in the matrix. A seven-grit experimental analogy of progressive cutting with the assessment of elastic and brittle modes of material removal, supplemented with the analysis of grinding force and surface micrographs, is a unique contribution to the work. Defect volume estimation using X-ray tomography, residual stress measurement using Raman Spectroscopy, and the hypothesis of skin level defects have also been discussed to provide a deeper insight into the micro mechanism of eccentric sleeve grinding.

在加工纤维增强聚合物复合材料（FRP）时，利用砂轮旋转的可控偏心进行渐进-间歇切削（简称为 "偏心套筒磨削"）被认为是将损伤降至最低的有效方法之一。本文通过详细研究磨料切削刃与纤维基质系统的渐进式相互作用，揭示了偏心套筒磨削的微观力学。本文的理论模型提供了对位于砂轮上的磨粒接触/切割行为的全面理解，砂轮在与基体以及嵌入基体中的纤维相互作用的过程中以微小的偏心率旋转。通过对材料去除的弹性和脆性模式进行评估，并辅以对磨削力和表面显微照片的分析，对渐进切削的七磨实验进行了类比，这是对这项工作的独特贡献。此外，还讨论了利用 X 射线断层扫描估算缺陷体积、利用拉曼光谱测量残余应力以及皮层缺陷假设等问题，以便更深入地了解偏心套筒磨削的微观机制。

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引用次数: 0