Pub Date : 2026-06-01Epub Date: 2026-02-06DOI: 10.1016/j.cirpj.2026.01.013
Sarah Christine Bermanschläger , Christian Baumann , Julian Brünner , Szilard Kolozsvari , Paul Heinz Mayrhofer , Friedrich Bleicher
Developing advanced hard coatings is crucial for improving machining performance. This study evaluates a newly created (Ti,Al,Ta,Ce)N coating realized by physical vapor deposition. Coated cemented carbide inserts were evaluated in dry longitudinal turning on C45E, benchmarked against TiN and (Ti,Al) at two cutting speeds (90 and 300 m·min−1) and two feeds (0.1 and 0.2 mm·rev−1). Tool wear, cutting forces, and rake face temperatures were monitored. At the cutting parameters of 300 m·min−1 and 0.2 mm·rev−1, the (Ti,Al,Ta,Ce)N coating outperformed (Ti,Al)N at a tool life of 750 m, reducing tool wear by 73 % and cutting forces by 11 %.
{"title":"Performance of TiN, (Ti,Al)N, and (Ti,Al,Ta,Ce)N coated tools in dry machining of C45E steel","authors":"Sarah Christine Bermanschläger , Christian Baumann , Julian Brünner , Szilard Kolozsvari , Paul Heinz Mayrhofer , Friedrich Bleicher","doi":"10.1016/j.cirpj.2026.01.013","DOIUrl":"10.1016/j.cirpj.2026.01.013","url":null,"abstract":"<div><div>Developing advanced hard coatings is crucial for improving machining performance. This study evaluates a newly created (Ti,Al,Ta,Ce)N coating realized by physical vapor deposition. Coated cemented carbide inserts were evaluated in dry longitudinal turning on C45E, benchmarked against TiN and (Ti,Al) at two cutting speeds (90 and 300 m·min<sup>−1</sup>) and two feeds (0.1 and 0.2 mm·rev<sup>−1</sup>). Tool wear, cutting forces, and rake face temperatures were monitored. At the cutting parameters of 300 m·min<sup>−1</sup> and 0.2 mm·rev<sup>−1</sup>, the (Ti,Al,Ta,Ce)N coating outperformed (Ti,Al)N at a tool life of 750 m, reducing tool wear by 73 % and cutting forces by 11 %.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"66 ","pages":"Pages 31-40"},"PeriodicalIF":5.4,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192684","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}
Drilling processes produce significant heat due to friction and material deformation, which can lead to tool wear, surface damage, and residual stress in the workpiece. To mitigate these effects, the peck drilling strategy was developed, incorporating periodic tool retractions to lower peak cutting temperatures and enhance chip evacuation. Consequently, accurate temperature distribution predictions are essential to improve drilling performance and ensure part quality. Few works in the literature focused on peck drilling operations, whose success is mainly influenced by the mitigation of the cutting temperature. To fill this gap, this study introduces a comprehensive predictive framework for evaluating cutting forces and temperatures in peck drilling. It combines an analytical force model with two distinct thermal analysis methods: an analytical technique and a Finite Volume Method (FVM) simulation. A novel oblique cutting model, grounded in Oxley’s machining theory and incorporating the Johnson–Cook material model, is proposed. The analytical thermal approach extends the infinitesimal point-source method to represent transient heat conduction in finite media, while the FVM simulation numerically models heat transfer and material removal dynamics. To validate the framework, an experimental campaign was conducted under various cutting conditions. Results demonstrate the model’s capability to reliably estimate cutting forces and temperature distributions across a wide range of parameters. The average prediction errors were 4.66% for cutting power, 7.45% for cutting forces, and for maximum temperature, 8% with the FVM and 11.64% using the analytical method. The developed framework lays the groundwork for future investigations into the impact of lubrication strategies on peck drilling.
{"title":"A predictive thermomechanical model for peck drilling","authors":"Mattia Pelosin , Alessandro Moramarco , Luca Bernini , Paolo Albertelli , Tommaso Lucchini","doi":"10.1016/j.cirpj.2026.02.002","DOIUrl":"10.1016/j.cirpj.2026.02.002","url":null,"abstract":"<div><div>Drilling processes produce significant heat due to friction and material deformation, which can lead to tool wear, surface damage, and residual stress in the workpiece. To mitigate these effects, the peck drilling strategy was developed, incorporating periodic tool retractions to lower peak cutting temperatures and enhance chip evacuation. Consequently, accurate temperature distribution predictions are essential to improve drilling performance and ensure part quality. Few works in the literature focused on peck drilling operations, whose success is mainly influenced by the mitigation of the cutting temperature. To fill this gap, this study introduces a comprehensive predictive framework for evaluating cutting forces and temperatures in peck drilling. It combines an analytical force model with two distinct thermal analysis methods: an analytical technique and a Finite Volume Method (FVM) simulation. A novel oblique cutting model, grounded in Oxley’s machining theory and incorporating the Johnson–Cook material model, is proposed. The analytical thermal approach extends the infinitesimal point-source method to represent transient heat conduction in finite media, while the FVM simulation numerically models heat transfer and material removal dynamics. To validate the framework, an experimental campaign was conducted under various cutting conditions. Results demonstrate the model’s capability to reliably estimate cutting forces and temperature distributions across a wide range of parameters. The average prediction errors were 4.66% for cutting power, 7.45% for cutting forces, and for maximum temperature, 8% with the FVM and 11.64% using the analytical method. The developed framework lays the groundwork for future investigations into the impact of lubrication strategies on peck drilling.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"66 ","pages":"Pages 70-85"},"PeriodicalIF":5.4,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192379","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}
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.’
{"title":"Manufacture process of Ti/Cu composite plates via prefabricated corrugated hot rolling and differential-temperature rolling","authors":"Peng Zhang , Tianfeng Wu , Zhongkai Ren , Hao Zhao , Wenwen Liu","doi":"10.1016/j.cirpj.2026.01.011","DOIUrl":"10.1016/j.cirpj.2026.01.011","url":null,"abstract":"<div><div>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.</div><div>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.’</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"66 ","pages":"Pages 1-17"},"PeriodicalIF":5.4,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146116624","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 : 2026-06-01Epub Date: 2026-02-10DOI: 10.1016/j.cirpj.2026.02.001
Hiroyuki Sakata , Péter Dobrovoczki , Daisuke Tsutsumi , András Kovács
In recent years, the manufacturing industry has faced increasing challenges related to labor shortages and rising labor costs. One response to these challenges is the automation of production systems, which replaces part of the human workforce with equipment such as robots, machine tools, and conveyors. However, designing an automated production system remains a complex task, often requiring engineers to manually develop an optimal system configuration and layout that minimizes investment costs while satisfying constraints such as production demand, technological requirements, and limited floor space. The traditional approach, solving system configuration and layout planning separately, often requires numerous iterations when floor space is restricted, making it difficult to obtain feasible solutions within a practical time frame. To address this issue, this study applies a recent logic-based Benders decomposition approach to a real industrial production system configuration and layout planning problem, involving the design of a machining cell composed of robots, machines, and other resources. The recently proposed abstract model is extended to capture all practically relevant requirements, including detailed modeling of resources and manufacturing processes. A case study demonstrates how the optimization software can be integrated into the overall planning workflow and highlights the refinements made by human experts to adapt the automatically computed solution to fulfill all practical requirements. The results show that, compared to the conventional manual workflow, the proposed optimization approach and software tool reduced the required human design effort from 22 working hours to 4.5 h.
{"title":"Production system configuration and layout planning for efficient manufacturing system design: An industrial case study","authors":"Hiroyuki Sakata , Péter Dobrovoczki , Daisuke Tsutsumi , András Kovács","doi":"10.1016/j.cirpj.2026.02.001","DOIUrl":"10.1016/j.cirpj.2026.02.001","url":null,"abstract":"<div><div>In recent years, the manufacturing industry has faced increasing challenges related to labor shortages and rising labor costs. One response to these challenges is the automation of production systems, which replaces part of the human workforce with equipment such as robots, machine tools, and conveyors. However, designing an automated production system remains a complex task, often requiring engineers to manually develop an optimal system configuration and layout that minimizes investment costs while satisfying constraints such as production demand, technological requirements, and limited floor space. The traditional approach, solving system configuration and layout planning separately, often requires numerous iterations when floor space is restricted, making it difficult to obtain feasible solutions within a practical time frame. To address this issue, this study applies a recent logic-based Benders decomposition approach to a real industrial production system configuration and layout planning problem, involving the design of a machining cell composed of robots, machines, and other resources. The recently proposed abstract model is extended to capture all practically relevant requirements, including detailed modeling of resources and manufacturing processes. A case study demonstrates how the optimization software can be integrated into the overall planning workflow and highlights the refinements made by human experts to adapt the automatically computed solution to fulfill all practical requirements. The results show that, compared to the conventional manual workflow, the proposed optimization approach and software tool reduced the required human design effort from 22 working hours to 4.5 h.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"66 ","pages":"Pages 56-69"},"PeriodicalIF":5.4,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192378","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 : 2026-06-01Epub Date: 2026-02-06DOI: 10.1016/j.cirpj.2026.01.010
Darshan S. , K.A. Desai , Abir Bhattacharyya
The chip formation during end milling is governed by cutting mechanics and process geometry. In the end milling of Carbon Fiber Reinforced Polymer (CFRP) composites, the chip formation mechanism depends on the embedded fiber configuration, including the instantaneous fiber orientation, the number of embedded fibers, and the length of the fibers interacting with the cutting edge. The existing uncut chip formulations often overlook the effects of fiber geometry parameters, resulting in an inadequate description of mechanics during the milling of CFRP. This work presents CFRP-specific formulations that explicitly distinguish the instantaneous undeformed chip geometry under different fiber configurations. The formulations redefine instantaneous uncut chip thickness and undeformed chip area along and across the fiber axis, enabling an accurate description of mechanics-based chip formation. The proposed chip geometry model can be employed to determine axial and transverse cutting force components. However, it is necessary to establish an explicit and interpretable mathematical relationship describing the variation of empirical coefficients with the newly introduced chip geometry parameters. This work proposes establishing these relationships using a Symbolic Regression approach. The forces predicted using fiber geometry-based chip formulations are compared with experimentally measured values under different fiber configurations. It has been shown that the predictions of the proposed approach are in good agreement with experimental results across diverse cutting conditions.
{"title":"Fiber-configuration-based chip geometry model for end milling of CFRP composites","authors":"Darshan S. , K.A. Desai , Abir Bhattacharyya","doi":"10.1016/j.cirpj.2026.01.010","DOIUrl":"10.1016/j.cirpj.2026.01.010","url":null,"abstract":"<div><div>The chip formation during end milling is governed by cutting mechanics and process geometry. In the end milling of Carbon Fiber Reinforced Polymer (CFRP) composites, the chip formation mechanism depends on the embedded fiber configuration, including the instantaneous fiber orientation, the number of embedded fibers, and the length of the fibers interacting with the cutting edge. The existing uncut chip formulations often overlook the effects of fiber geometry parameters, resulting in an inadequate description of mechanics during the milling of CFRP. This work presents CFRP-specific formulations that explicitly distinguish the instantaneous undeformed chip geometry under different fiber configurations. The formulations redefine instantaneous uncut chip thickness and undeformed chip area along and across the fiber axis, enabling an accurate description of mechanics-based chip formation. The proposed chip geometry model can be employed to determine axial and transverse cutting force components. However, it is necessary to establish an explicit and interpretable mathematical relationship describing the variation of empirical coefficients with the newly introduced chip geometry parameters. This work proposes establishing these relationships using a Symbolic Regression approach. The forces predicted using fiber geometry-based chip formulations are compared with experimentally measured values under different fiber configurations. It has been shown that the predictions of the proposed approach are in good agreement with experimental results across diverse cutting conditions.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"66 ","pages":"Pages 18-30"},"PeriodicalIF":5.4,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192380","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 : 2026-06-01Epub Date: 2026-02-07DOI: 10.1016/j.cirpj.2026.01.008
Jingxuan Zhang , Wei Xiao , Junli Li , Gang Liu , Liqiang Zhang
To address accuracy and efficiency challenges in trajectory planning for composite material Automated Fiber Placement (AFP), this study proposes a surface path generation method integrating Non-Uniform Rational B-Splines (NURBS)-based parametric modeling with multimodal mesh quality assessment. NURBS surfaces are constructed and an optimized Loop subdivision algorithm is applied to generate multi-scale meshes, effectively mitigating defects such as inter-tow gaps and overlaps arising from insufficient mesh refinement in conventional approaches. A comprehensive evaluation framework is established by combining two-dimensional(2D) texture features extracted via the Gray Level Co-occurrence Matrix (GLCM) with spatial mesh geometric information to quantitatively analyze the impact of mesh quality on the AFP process. Evaluation results demonstrate that high-quality mesh samples significantly reduce inter-tow gaps and overlap defects during placement testing, achieving over a 20 % reduction in defect severity compared to traditional STL meshes. This provides an assessment scheme that balances geometric precision and computational efficiency for complex-surface AFP processes.
{"title":"Texture-geometry-based mesh quality assessment for automated fiber placement","authors":"Jingxuan Zhang , Wei Xiao , Junli Li , Gang Liu , Liqiang Zhang","doi":"10.1016/j.cirpj.2026.01.008","DOIUrl":"10.1016/j.cirpj.2026.01.008","url":null,"abstract":"<div><div>To address accuracy and efficiency challenges in trajectory planning for composite material Automated Fiber Placement (AFP), this study proposes a surface path generation method integrating Non-Uniform Rational B-Splines (NURBS)-based parametric modeling with multimodal mesh quality assessment. NURBS surfaces are constructed and an optimized Loop subdivision algorithm is applied to generate multi-scale meshes, effectively mitigating defects such as inter-tow gaps and overlaps arising from insufficient mesh refinement in conventional approaches. A comprehensive evaluation framework is established by combining two-dimensional(2D) texture features extracted via the Gray Level Co-occurrence Matrix (GLCM) with spatial mesh geometric information to quantitatively analyze the impact of mesh quality on the AFP process. Evaluation results demonstrate that high-quality mesh samples significantly reduce inter-tow gaps and overlap defects during placement testing, achieving over a 20 % reduction in defect severity compared to traditional STL meshes. This provides an assessment scheme that balances geometric precision and computational efficiency for complex-surface AFP processes.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"66 ","pages":"Pages 41-55"},"PeriodicalIF":5.4,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192374","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 : 2026-04-01Epub Date: 2025-12-27DOI: 10.1016/j.cirpj.2025.12.011
Xinzhuang Wang, Changjuan Zhang, Feng Jiao, Yuxiao Qiu, Kanghui Liu
As a super - hard material, cemented carbide has high hardness and low fracture toughness. When processed using traditional methods, it is characterized by low efficiency, high cost, and poor quality. This paper proposes a laser - ultrasonic composite milling (LUCM) machining process to improve the ultra - precision machining performance of cemented carbide. The motion characteristics of ultrasonic vibration and the characteristics of laser preheating were analyzed, and a theoretical milling force model was established, with prediction results having an error of less than 10 %. Compared to conventional milling (CM), ultrasonic assisted milling (UAM), and laser assisted milling (LAM), the main milling force (Fx), radial force (Fy), and axial force (Fz) values of LUCM were reduced by 23.49 % – 58.50 %, 6.90 % – 39.79 %, and 13.07 % – 29.44 %, respectively. Tool life was extended by 91.63 %, 44.65 %, and 29.46 %, respectively, and surface roughness was reduced by up to 33.05 %. According to the response surface method (RSM) analysis, when the laser power (LP) was 345.775 W, the laser beam diameter (LBD) was 0.236 mm, the distance from laser spot center (DFLSC) was 0.059 mm, and the ultrasonic amplitude (UA) was 2.065μm, the minimum value of the optimized Fx was 70.452 N. In addition, the experimental data were fitted and trained using an artificial neural network (ANN), and the results showed that the experimental and fitted values were highly consistent, with an error of less than ± 2.
{"title":"Research on cutting force characteristics and parameter optimization of laser-ultrasonic composite milling of cemented carbide","authors":"Xinzhuang Wang, Changjuan Zhang, Feng Jiao, Yuxiao Qiu, Kanghui Liu","doi":"10.1016/j.cirpj.2025.12.011","DOIUrl":"10.1016/j.cirpj.2025.12.011","url":null,"abstract":"<div><div>As a super - hard material, cemented carbide has high hardness and low fracture toughness. When processed using traditional methods, it is characterized by low efficiency, high cost, and poor quality. This paper proposes a laser - ultrasonic composite milling (LUCM) machining process to improve the ultra - precision machining performance of cemented carbide. The motion characteristics of ultrasonic vibration and the characteristics of laser preheating were analyzed, and a theoretical milling force model was established, with prediction results having an error of less than 10 %. Compared to conventional milling (CM), ultrasonic assisted milling (UAM), and laser assisted milling (LAM), the main milling force (<em>Fx</em>), radial force (<em>Fy</em>), and axial force (<em>Fz</em>) values of LUCM were reduced by 23.49 % – 58.50 %, 6.90 % – 39.79 %, and 13.07 % – 29.44 %, respectively. Tool life was extended by 91.63 %, 44.65 %, and 29.46 %, respectively, and surface roughness was reduced by up to 33.05 %. According to the response surface method (RSM) analysis, when the laser power (LP) was 345.775 W, the laser beam diameter (LBD) was 0.236 mm, the distance from laser spot center (DFLSC) was 0.059 mm, and the ultrasonic amplitude (UA) was 2.065μm, the minimum value of the optimized <em>Fx</em> was 70.452 N. In addition, the experimental data were fitted and trained using an artificial neural network (ANN), and the results showed that the experimental and fitted values were highly consistent, with an error of less than ± 2.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"65 ","pages":"Pages 18-41"},"PeriodicalIF":5.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842468","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 : 2026-04-01Epub Date: 2026-01-24DOI: 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.
{"title":"Suppression of chatter in thin-walled component milling through shear thickening fluids","authors":"Shuqi Wang , Shengjie Zhou , Dongliang Gao , Xiaoqiu Xu , Chunlei He","doi":"10.1016/j.cirpj.2026.01.007","DOIUrl":"10.1016/j.cirpj.2026.01.007","url":null,"abstract":"<div><div>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.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"65 ","pages":"Pages 238-260"},"PeriodicalIF":5.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146078293","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 : 2026-04-01Epub Date: 2026-01-19DOI: 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.
{"title":"Surface quality classification in burnished aluminum alloys based on nonlinear dynamic characteristics and machine learning","authors":"Cong Ding , Shiqing Feng , Xing Liu , Michael G. Bryant , Yan Zhao , Jianfei Han , Zhongyu Piao","doi":"10.1016/j.cirpj.2026.01.005","DOIUrl":"10.1016/j.cirpj.2026.01.005","url":null,"abstract":"<div><div>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 (λ<sub>max</sub>>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.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"65 ","pages":"Pages 223-237"},"PeriodicalIF":5.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023611","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 : 2026-04-01Epub Date: 2025-12-27DOI: 10.1016/j.cirpj.2025.12.013
Amir Hossein Sakhaei, Hamid Baseri, Mohammad Javad Mirnia
In burnishing process, due to local deformation and ball rolling, material is subjected to complex stress state and different stress components are applied to the workpiece. Under these loading conditions, material enters the plastic zone and accumulation of plastic strain leads to the development of damage within the workpiece. Damage prediction in multi-stage processes is challenging. In this work, modeling of process was performed using finite element (FE) method and contact mechanics theory. Little research has been done on the mechanism of damage accumulation in burnishing, so the aim of this work is to investigate the process mechanics and damage prediction using a nonlinear model. The damage model was defined by the VUSDFLD subroutine in Abaqus software. The effect of reverse loading on damage growth and the accuracy of predicting failure onset was investigated. Deformation mechanics indicate severe changes in the stress state, which should be considered in the calibration of damage criterion. Therefore, the nonlinear model was calibrated by a new test appropriate to the loading in burnishing. According to the results, using the nonlinear criterion and choosing the damage formation threshold of , the critical penetration depth was predicted with an error of 4.54 %. The effect of threshold value on the moment and location of failure initiation is significant, such that its non-definition led to an error of 36.4 % in predicting the critical penetration depth. Plastic strain was used to estimate the work hardening. The variations in plastic strain along the thickness correspond to hardness distribution in workpiece.
{"title":"Numerical modeling of damage accumulation mechanism in ball burnishing with undefined ball motion of AA6061-T6","authors":"Amir Hossein Sakhaei, Hamid Baseri, Mohammad Javad Mirnia","doi":"10.1016/j.cirpj.2025.12.013","DOIUrl":"10.1016/j.cirpj.2025.12.013","url":null,"abstract":"<div><div>In burnishing process, due to local deformation and ball rolling, material is subjected to complex stress state and different stress components are applied to the workpiece. Under these loading conditions, material enters the plastic zone and accumulation of plastic strain leads to the development of damage within the workpiece. Damage prediction in multi-stage processes is challenging. In this work, modeling of process was performed using finite element (FE) method and contact mechanics theory. Little research has been done on the mechanism of damage accumulation in burnishing, so the aim of this work is to investigate the process mechanics and damage prediction using a nonlinear model. The damage model was defined by the VUSDFLD subroutine in Abaqus software. The effect of reverse loading on damage growth and the accuracy of predicting failure onset was investigated. Deformation mechanics indicate severe changes in the stress state, which should be considered in the calibration of damage criterion. Therefore, the nonlinear model was calibrated by a new test appropriate to the loading in burnishing. According to the results, using the nonlinear criterion and choosing the damage formation threshold of <span><math><mrow><mo>−</mo><mfrac><mrow><mn>2</mn></mrow><mrow><mn>3</mn></mrow></mfrac></mrow></math></span>, the critical penetration depth was predicted with an error of 4.54 %. The effect of threshold value on the moment and location of failure initiation is significant, such that its non-definition led to an error of 36.4 % in predicting the critical penetration depth. Plastic strain was used to estimate the work hardening. The variations in plastic strain along the thickness correspond to hardness distribution in workpiece.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"65 ","pages":"Pages 42-69"},"PeriodicalIF":5.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842469","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}
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