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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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引用次数: 0
A grey-box approach based on Johnson-Cook constitutive model to improve predictions of mechanical loads of cutting simulations for normalized AISI 1045 基于Johnson-Cook本构模型的灰盒方法改进标准化aisi1045切削模拟机械载荷预测
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-01-07 DOI: 10.1016/j.cirpj.2025.12.014
Jan Wolf , Erik Krumme , Nithin Kumar Bandaru , Martin Dienwiebel , Andreas Zabel , Hans-Christian Möhring
In machining, high temperatures and strain rates impact the flow stress of the workpiece material, making it essential to understand the materials behaviour in these process conditions for meaningful finite element analysis (FEA) of the cutting process. The Johnson-Cook constitutive model, despite being the most widely applied, is reported to struggle in capturing the material behaviour outside of the reference conditions it was calibrated on. However determining these parameters in conventional material tests is challenging. To solve this issue, this study proposes a grey-box approach which aims to increase the accuracy of process force prediction of FEA, employing a Johnson-Cook model determined by experiments conducted on a Split-Hopkins Pressure Bar and compression tests at elevated temperatures on a Gleeble 3800c for AISI 1045, over a variety of cutting parameters. In total 110 cutting experiments and their corresponding simulations were carried out in a fully factorial experimental design with eleven cutting speeds and ten uncut chip thicknesses. Succeeding the white-box model, a black box model is trained to capture the non-linear behaviour between the simulation and the cutting experiments. Among the tested algorithms, XGBoost and Support Vector Regression outperformed Random Forests and Neural Network for predicting cutting force and feed force. The proposed grey-box approach showed an improved capability of predicting cutting force and feed force, reducing the mean absolute error and mean squared error compared to the white-box model by 97.9 % and 99.9 % for cutting force and by 94.9 % and 99.7 % for feed force, respectively. The grey-box model achieved a mean error of 1.3 % with a standard deviation of 0.1 in process force prediction.
在机械加工中,高温和应变率会影响工件材料的流动应力,因此了解这些工艺条件下的材料行为对于切削过程的有意义的有限元分析(FEA)至关重要。Johnson-Cook本构模型尽管应用最为广泛,但据报道,它难以捕捉其校准的参考条件之外的材料行为。然而,在常规材料测试中确定这些参数是具有挑战性的。为了解决这一问题,本研究提出了一种灰盒方法,旨在提高有限元分析过程力预测的准确性,采用Johnson-Cook模型,该模型是通过在Split-Hopkins压力棒上进行的实验和在Gleeble 3800℃的AISI 1045上进行的高温压缩试验确定的。在全析因试验设计中,共进行了110次切削实验并进行了相应的仿真,实验设计有11种切削速度和10种未切削切屑厚度。在白盒模型之后,训练了一个黑盒模型来捕捉仿真和切割实验之间的非线性行为。在测试算法中,XGBoost和支持向量回归在预测切削力和进给力方面优于随机森林和神经网络。提出的灰盒方法预测切削力和进给力的能力有所提高,与白盒模型相比,切削力的平均绝对误差和均方误差分别降低了97.9% %和99.9 %,进给力的平均绝对误差和均方误差分别降低了94.9% %和99.7 %。灰盒模型在工艺力预测中的平均误差为1.3 %,标准差为0.1。
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引用次数: 0
Finite element modeling of indexable insert drilling processes in stainless steel 不锈钢可转位刀片钻孔过程的有限元建模
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-01-05 DOI: 10.1016/j.cirpj.2025.12.018
Mikel Etxebeste , Gorka Ortiz-de-Zarate , Homar Lopez-Hawa , Pedro J. Arrazola
Indexable insert drills play a crucial role in high-performance drilling, particularly for large-diameter holes and difficult-to-machine materials. Although FEM is a powerful tool for analyzing and optimizing drilling processes, limited research has focused on indexable insert drills, and the efficient simulation of large-diameter drills with complex cutting geometries remains a significant challenge. This study presents an optimized and computationally efficient FEM model for indexable insert drills, developed in AdvantEdge™ 3D, capable of predicting thermomechanical loads (thrust force, torque, stress, temperature) and chip morphology during drilling and redrilling of AISI 316 L stainless steel. The key innovation lies in a computational approach that significantly reduces simulation time while maintaining high predictive accuracy. The model incorporates a novel tool–workpiece configuration with a slotted workpiece that enables the drill to reach nominal feed rate immediately upon engagement, accelerating convergence toward thermomechanical steady-state. Model optimization was achieved through a systematic evaluation of the most influential input parameters, surpassing the capabilities of previous FEM approaches and providing new validated insight into drilling process modeling. A comprehensive sensitivity analysis of Johnson–Cook flow stress parameters, friction coefficients, and mesh size was performed to optimize both accuracy and computational efficiency. The model was experimentally validated through complete-drill tests (both inserts mounted) and novel single-insert tests (one insert mounted) across a wide range of cutting conditions, including redrilling with varying pilot hole diameters. The optimized model accurately predicts torque, thrust forces, and chip morphology (average error: 16 %), while providing detailed stress and temperature distributions. Thrust force underprediction remains the primary limitation, identified as originating from the central insert, where Build-Up Edge (BUE) formation was observed at low cutting speeds near the drill tip.
可转位镶钻在高性能钻孔中发挥着至关重要的作用,特别是对于大直径孔和难以加工的材料。虽然有限元分析是分析和优化钻孔工艺的有力工具,但有限的研究集中在可转位镶齿钻头上,并且具有复杂切削几何形状的大直径钻头的有效模拟仍然是一个重大挑战。本研究提出了一个优化的、计算效率高的可转位嵌套钻头有限元模型,该模型是在AdvantEdge™3D中开发的,能够预测AISI 316 L不锈钢在钻削和再钻削过程中的热机械载荷(推力、扭矩、应力、温度)和切屑形态。关键的创新在于一种计算方法,可以在保持高预测精度的同时显着减少模拟时间。该模型结合了一种新颖的工具-工件配置,具有开槽工件,使钻头在啮合后立即达到标称进给速率,加速了向热机械稳态的收敛。通过对最具影响力的输入参数进行系统评估,实现了模型优化,超越了之前FEM方法的能力,并为钻井过程建模提供了新的验证见解。对Johnson-Cook流动应力参数、摩擦系数和网格尺寸进行了综合敏感性分析,以优化精度和计算效率。该模型通过全钻测试(安装了两个钻头)和新型单钻头测试(安装了一个钻头)在各种切削条件下进行了实验验证,包括在不同的导孔直径下进行重钻。优化后的模型准确地预测了扭矩、推力和芯片形态(平均误差:16 %),同时提供了详细的应力和温度分布。推力预测不足仍然是主要的限制因素,主要原因是中心镶齿,在钻头尖端附近低切削速度下观察到积聚边缘(BUE)地层。
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引用次数: 0
Intelligent interpretable milling force prediction: A method based on vibration signals fusing data-driven and physical features 智能可解释铣削力预测:一种基于振动信号融合数据驱动和物理特征的方法
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2026-01-03 DOI: 10.1016/j.cirpj.2025.12.020
Wen Hou , Tong Zhu , Jiachang Wang , Song Zhang
To address the limitations in accuracy and interpretability of milling force prediction, this research proposes HyDCFF-Net, an interpretable model integrating physical time-frequency features with deep learning. First, vibration signals are processed using sliding windows, and a dual-channel neural network is developed to fuse these features, establishing a robust nonlinear mapping to milling force. Next, the Captum framework provides interpretability by visualizing feature contributions. Finally, extensive experiments under varied conditions validate its high prediction accuracy and strong generalization, achieving R² scores above 0.98 on primary tests with robust cross-dataset performance, demonstrating its effectiveness as a reliable milling force monitoring solution.
为了解决铣削力预测精度和可解释性的局限性,本研究提出了HyDCFF-Net,这是一种将物理时频特征与深度学习相结合的可解释模型。首先,利用滑动窗对振动信号进行处理,并建立双通道神经网络来融合这些特征,建立强健的非线性铣削力映射。接下来,Captum框架通过可视化特性贡献来提供可解释性。最后,在不同条件下的大量实验验证了该方法的预测精度高,泛化能力强,在主要测试中R²得分在0.98以上,具有良好的跨数据集性能,证明了该方法是一种可靠的铣削力监测解决方案的有效性。
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引用次数: 0
Comprehensive analysis of friction stir deposited Inconel 600: Thermal, structural, and mechanical insights 综合分析搅拌摩擦沉积Inconel 600:热,结构和机械的见解
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2025-12-30 DOI: 10.1016/j.cirpj.2025.12.016
Neeraj K. Mishra, Jignesh Nakrani, Amber Shrivastava
Solid-state deposition is one of the promising research areas. Here, the material does not melt during the process; instead, the material is plasticized to achieve the desired deformation. The present work employs friction stir metal deposition to create a three-dimensional wall structure of Inconel 600 through layer-by-layer deposition. A defect-free, fully consolidated wall without visible voids was deposited with more than 100 layers. The deposition was performed at 2500 RPM, with a 5 mm/min plunge feed and a 220 mm/min forward feed rate. The layer thickness was found to be decreasing in the build direction. Thermal history showed that layer deposition reheats the substrate and previously deposited layers. The temperature in the deposited wall varies in deposition and build direction. The heating-cooling cycle at the ends of the deposit is very different from the remaining portion of the deposit. Ends are exposed to higher temperatures for relatively shorter periods and once in every layer of deposition. In contrast, the remaining deposition is exposed to higher temperatures for a more extended period and twice in one layer of deposition. Also, a tool with an associated flash (Tool-flash) affects the heating of layers. The tool-flash's leading edge has a lower temperature than the tool flash's trailing edge, and the material beneath the tool-flash is heated cyclically. Microstructural investigation explained the effect of this non-uniformity of temperature in the grain morphology. Electron back scattered diffraction (EBSD) showed dynamic recrystallization-driven grain refinement where the grain size of the base material was 16–22μm, which changed to a final grain size of 8.3μm after FSMD. Further investigation along the build direction showed a trend of increasing grain size from the bottom towards the top with some alternate bands of fine grain region near the interface. Grains near the interface were as small as 0.1 μm. Electron backscattered diffraction (EBSD) results also showed that most of the grains were equiaxed with the presence of twin boundaries. Microhardness measurement showed decreasing trend along build direction, which is inline with the grain morphology and Hall Petch’s relationship. The tensile strength of deposition in the longitudinal direction showed comparable mechanical properties with the base material with a deposition efficiency of 78.3 %. Fractography of the failed samples showed ductile fracture with the significant presence of dimples and some parabolic dimples due to some delamination of layers. Energy dispersive spectroscopy results showed no elemental segregation, which was confirmed with uniform element distribution on the fracture surface.
固态沉积是一个很有前途的研究领域。在这里,材料在加工过程中不会熔化;相反,材料被塑化以达到所需的变形。本研究采用摩擦搅拌金属沉积法,逐层沉积,形成了英科乃尔600的三维壁面结构。一个无缺陷、完全固结、没有可见空隙的墙体被沉积了100多层。沉积的转速为2500 RPM,进料速度为5 mm/min,进料速度为220 mm/min。层厚在构建方向呈减小趋势。热历史表明,层沉积使基底和先前沉积的层重新加热。沉积壁内的温度随沉积和构筑方向的不同而变化。沉积物末端的加热-冷却循环与沉积物的其余部分非常不同。在每一层沉积中,末端暴露在较高温度下的时间相对较短。相比之下,剩余的沉积在更高的温度下暴露更长的时间,在一层沉积中暴露两次。此外,带有相关闪光(tool -flash)的工具会影响层的加热。工具闪片前缘的温度低于工具闪片后缘的温度,并且工具闪片下方的材料被循环加热。显微组织研究解释了这种温度不均匀性对晶粒形貌的影响。电子背散射衍射(EBSD)显示出再结晶驱动的晶粒细化过程,基材的晶粒尺寸为16 ~ 22μm, FSMD后最终晶粒尺寸为8.3μm。进一步研究表明,沿构筑方向晶粒尺寸呈自下而上增大的趋势,在界面附近有一些细晶粒区域的交替带。界面附近晶粒小至0.1 μm。电子背散射衍射(EBSD)结果也表明,大多数晶粒是等轴的,存在孪晶界。显微硬度测量结果显示,沿铸模方向呈下降趋势,这与晶粒形貌和霍尔-佩奇关系一致。沉积的纵向抗拉强度与基材相当,沉积效率为78.3% %。失效试样的断口形貌显示韧性断裂,由于层的分层,存在明显的韧窝和一些抛物型韧窝。能量色散分析结果表明,断口表面元素分布均匀,没有元素偏析。
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引用次数: 0
Effects of composition, recycling and processing on deep drawing performance of automotive 6016 aluminium sheets 成分、回收和加工对汽车用6016铝板拉深性能的影响
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2025-12-29 DOI: 10.1016/j.cirpj.2025.12.012
Angela Thum , Emir Hodžić , Josef Domitner , Stefan Pogatscher
The ability to undergo complex forming operations without failure due to necking or cracking is an essential feature for automotive sheet material. The present study examines the effects of chemical composition and processing parameters on the mechanical properties of industrial 6016 aluminium sheets. The homogenization process and the Mn content were used to investigate the influence of dispersoids. Moreover, the solution treatment, the Si content and the use of recycling-friendly compositions were studied. A (semi-)industrial scale deep drawing tool with a fixed drawing depth and varying blank holder force was used to characterize the formability of the sheets at different drawing speeds. An analysis of the strain hardening behaviour via Kocks-Mecking plots revealed remarkable predictive power, enabling the estimation of the behaviour under complex sheet forming conditions from tensile testing. Microstructural investigations demonstrated that dispersoids or constituent particles exerted a minimal influence on strain hardening at high degrees of deformation, whereas dissolved Si exerted a significant influence, resulting in markedly enhanced forming performance. This is linked to the suppression of dynamic recovery, which in turn leads to the interesting results that an alloy produced with higher recycled content performed very well.
能够经受复杂的成形操作而不因颈缩或开裂而失效是汽车板材材料的基本特征。本研究考察了化学成分和加工参数对工业6016铝板机械性能的影响。采用均质化工艺和Mn含量考察了分散体的影响。此外,还研究了固溶处理、硅含量和循环友好型成分的使用。采用固定拉深和不同压边力的(半)工业规模拉深工具,对不同拉深速度下板材的成形性能进行了表征。通过Kocks-Mecking图分析应变硬化行为显示出显著的预测能力,可以通过拉伸测试估计复杂板料成形条件下的行为。显微组织研究表明,在高度变形时,分散体或组成颗粒对应变硬化的影响很小,而溶解的Si对应变硬化的影响很大,从而显著提高了成形性能。这与动态恢复的抑制有关,这反过来又导致了有趣的结果,即具有较高回收含量的合金性能非常好。
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CIRP Journal of Manufacturing Science and Technology
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