CIRP Journal of Manufacturing Science and Technology最新文献

英文中文

Investigation of surface damage mechanisms in milling heat-treated pine wood

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.2024.11.005

Feng Zhang , Tianlan Zhang , Dietrich Buck , Yunhui Bao , Xiaolei Guo

Heat-treated pine wood is commonly utilized in the furniture and construction sectors, with milling being a key technique to enhance the surface quality of these products. To investigate the milling surface damage mechanism of heat-treated wood, a milling test of pine wood was conducted after different heat treatments, and the effects of heat treatment temperature and cutting parameters (cutting depth and feed per tooth) on cutting force and surface roughness were analyzed. The experimental and analytical results of these cutting tests indicate that higher heat treatment temperature resulted in reduced wood strength, leading to a reduction in cutting force as the heat treatment temperature increased. Additionally, the brittleness of wood increased with increasing heat-treatment temperature, which caused more burrs and wood tissue fragments to appear on the machined surface, resulting in increased surface roughness. Increasing cutting depth from 0.1 mm to 0.5 mm raises cutting force and surface roughness for untreated and heat-treated wood. For depth, force increases by 35.5% to 15.32% and roughness by 75.8% to 84.7%. For feed speed from 0.2 mm/Z to 0.6 mm/Z, force increases by 37.55% to 34.56% and roughness by 58.38% to 91.4%. This study investigates the milling surface damage mechanisms of heat-treated wood, filling the gap in the literature that has focused on the effects of cutting parameters on surface roughness without examining surface damage mechanisms, providing a theoretical basis for optimizing the processing technology of heat-treated wood.

{"title":"Investigation of surface damage mechanisms in milling heat-treated pine wood","authors":"Feng Zhang , Tianlan Zhang , Dietrich Buck , Yunhui Bao , Xiaolei Guo","doi":"10.1016/j.cirpj.2024.11.005","DOIUrl":"10.1016/j.cirpj.2024.11.005","url":null,"abstract":"<div><div>Heat-treated pine wood is commonly utilized in the furniture and construction sectors, with milling being a key technique to enhance the surface quality of these products. To investigate the milling surface damage mechanism of heat-treated wood, a milling test of pine wood was conducted after different heat treatments, and the effects of heat treatment temperature and cutting parameters (cutting depth and feed per tooth) on cutting force and surface roughness were analyzed. The experimental and analytical results of these cutting tests indicate that higher heat treatment temperature resulted in reduced wood strength, leading to a reduction in cutting force as the heat treatment temperature increased. Additionally, the brittleness of wood increased with increasing heat-treatment temperature, which caused more burrs and wood tissue fragments to appear on the machined surface, resulting in increased surface roughness. Increasing cutting depth from 0.1 mm to 0.5 mm raises cutting force and surface roughness for untreated and heat-treated wood. For depth, force increases by 35.5% to 15.32% and roughness by 75.8% to 84.7%. For feed speed from 0.2 mm/Z to 0.6 mm/Z, force increases by 37.55% to 34.56% and roughness by 58.38% to 91.4%. This study investigates the milling surface damage mechanisms of heat-treated wood, filling the gap in the literature that has focused on the effects of cutting parameters on surface roughness without examining surface damage mechanisms, providing a theoretical basis for optimizing the processing technology of heat-treated wood.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"56 ","pages":"Pages 47-60"},"PeriodicalIF":4.6,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143183558","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}

引用次数: 0

Ultra-precision surface treatment of beta-titanium alloy printed using laser and electron beam melting sources

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-01-31 DOI: 10.1016/j.cirpj.2025.01.006

Jibin Boban , Afzaal Ahmed , Ozkan Gokcekaya , Takayoshi Nakano

Additive Manufacturing (AM) is a near net shape fabrication technology offering exceptional design freedom for complex part production. However, the inadequate surface quality and poorly generated micro-features adversely affect the functional performance of metal AM parts thereby restricting the direct adoption in biomedical implantation applications. Ultra-precision diamond turning (UPDT) can be regarded as a possible solution to overcome the aforementioned challenges in metal AM. However, the machinability of metal AM parts at ultra-precision level is highly sensitive to the material specific attributes and microstructure generated by the thermal characteristics of the process. In light of this, the present study follows a novel direction by investigating the dependence of distinct material characteristics imparted by two different AM powder melting sources on the ultra-precision post-treatment performance. Experiments were conducted on laser and electron beam printed beta-Ti alloy (Ti-15Mo-5Zr-3Al) which has potential importance in biomedical applications. The results demonstrate that the microstructural variations in respective samples affect the process performance and final surface integrity. The samples printed using laser powder bed fusion (LPBF) achieved a final surface finish (Sa) of ∼66.3 nm after UPDT relative to the electron beam powder bed fusion (EPBF) samples (∼104.3 nm). The cutting forces tends to exhibit sharp dip in forces in case of LPBF samples when micro-cutting was done perpendicular to the beam scanning direction. The chip morphology analysis corresponding to the LPBF and EPBF samples substantiates the generation of chips with segmentation/serrations on the free chip surface and parent material adhesion on the tool-chip contact surface. Further, precise microfeature generation was successfully accomplished on both the samples with minimal dimensional deviations on LPBF sample. Thus, the outcomes of the study establish the potential of UPDT in elevating the bioimplant surface standards of beta-Ti alloy with superior performance in LPBF samples.

{"title":"Ultra-precision surface treatment of beta-titanium alloy printed using laser and electron beam melting sources","authors":"Jibin Boban , Afzaal Ahmed , Ozkan Gokcekaya , Takayoshi Nakano","doi":"10.1016/j.cirpj.2025.01.006","DOIUrl":"10.1016/j.cirpj.2025.01.006","url":null,"abstract":"<div><div>Additive Manufacturing (AM) is a near net shape fabrication technology offering exceptional design freedom for complex part production. However, the inadequate surface quality and poorly generated micro-features adversely affect the functional performance of metal AM parts thereby restricting the direct adoption in biomedical implantation applications. Ultra-precision diamond turning (UPDT) can be regarded as a possible solution to overcome the aforementioned challenges in metal AM. However, the machinability of metal AM parts at ultra-precision level is highly sensitive to the material specific attributes and microstructure generated by the thermal characteristics of the process. In light of this, the present study follows a novel direction by investigating the dependence of distinct material characteristics imparted by two different AM powder melting sources on the ultra-precision post-treatment performance. Experiments were conducted on laser and electron beam printed beta-Ti alloy (Ti-15Mo-5Zr-3Al) which has potential importance in biomedical applications. The results demonstrate that the microstructural variations in respective samples affect the process performance and final surface integrity. The samples printed using laser powder bed fusion (LPBF) achieved a final surface finish (Sa) of ∼66.3 nm after UPDT relative to the electron beam powder bed fusion (EPBF) samples (∼104.3 nm). The cutting forces tends to exhibit sharp dip in forces in case of LPBF samples when micro-cutting was done perpendicular to the beam scanning direction. The chip morphology analysis corresponding to the LPBF and EPBF samples substantiates the generation of chips with segmentation/serrations on the free chip surface and parent material adhesion on the tool-chip contact surface. Further, precise microfeature generation was successfully accomplished on both the samples with minimal dimensional deviations on LPBF sample. Thus, the outcomes of the study establish the potential of UPDT in elevating the bioimplant surface standards of beta-Ti alloy with superior performance in LPBF samples.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"58 ","pages":"Pages 1-19"},"PeriodicalIF":4.6,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143105131","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}

引用次数: 0

The process, microstructure, and mechanical properties of hybrid manufacturing for steel injection mold components

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-01-23 DOI: 10.1016/j.cirpj.2025.01.004

Zhouyi Xiang , Min Chen , Lei Wang , Mingdi Wang , Liqiao Li

The traditional injection molding industry primarily utilizes subtractive manufacturing processes to ensure the quality of molds, which often requires high expenses. With the rapid development of additive manufacturing, the integration of additive and subtractive processes, known as hybrid manufacturing, has emerged as a new trend. This new approach necessitates comprehensive quality characterization of the produced components. This paper investigates the feasibility of hybrid manufacturing for core mold components subjected to cyclic loading conditions, utilizing laser cladding and machining. The study evaluates multiple indicators through a blend of experimental and simulation methods to assess and validate the effectiveness and practicality of the manufacturing process. In summary, the findings indicate that laser cladding technology provides high-quality, dense cladding layers with an average porosity below 0.1 %, demonstrating strong potential for industrial applications. Electron Back Scatter Diffraction (EBSD) analysis shows that the cladding layer has a larger grain size than the substrate material, consistent with microhardness tests that reveal lower hardness values in the cladding layer (mostly below 500 HV) compared to the substrate area (exceeding 500 HV) due to the process's high temperatures. Fatigue tests revealed that fit type has a significant impact on fatigue performance. Although the simulated fatigue life curve predicted a shorter life than observed experimentally, it followed a similar trend.

{"title":"The process, microstructure, and mechanical properties of hybrid manufacturing for steel injection mold components","authors":"Zhouyi Xiang , Min Chen , Lei Wang , Mingdi Wang , Liqiao Li","doi":"10.1016/j.cirpj.2025.01.004","DOIUrl":"10.1016/j.cirpj.2025.01.004","url":null,"abstract":"<div><div>The traditional injection molding industry primarily utilizes subtractive manufacturing processes to ensure the quality of molds, which often requires high expenses. With the rapid development of additive manufacturing, the integration of additive and subtractive processes, known as hybrid manufacturing, has emerged as a new trend. This new approach necessitates comprehensive quality characterization of the produced components. This paper investigates the feasibility of hybrid manufacturing for core mold components subjected to cyclic loading conditions, utilizing laser cladding and machining. The study evaluates multiple indicators through a blend of experimental and simulation methods to assess and validate the effectiveness and practicality of the manufacturing process. In summary, the findings indicate that laser cladding technology provides high-quality, dense cladding layers with an average porosity below 0.1 %, demonstrating strong potential for industrial applications. Electron Back Scatter Diffraction (EBSD) analysis shows that the cladding layer has a larger grain size than the substrate material, consistent with microhardness tests that reveal lower hardness values in the cladding layer (mostly below 500 HV) compared to the substrate area (exceeding 500 HV) due to the process's high temperatures. Fatigue tests revealed that fit type has a significant impact on fatigue performance. Although the simulated fatigue life curve predicted a shorter life than observed experimentally, it followed a similar trend.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"57 ","pages":"Pages 90-99"},"PeriodicalIF":4.6,"publicationDate":"2025-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143175563","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}

引用次数: 0

Production scheduling of additively manufactured metal parts

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-01-23 DOI: 10.1016/j.cirpj.2025.01.005

Kuo-Ching Ying , Shih-Wei Lin , Pourya Pourhejazy , Fei-Huan Lee

The production of metal products is one of the main areas where supply chains benefit from adopting additive manufacturing (AM). Optimizing the production process facilitates the widespread adoption of AM by improving know-how and reducing costs. This study offers a twofold contribution to facilitate the implementation of Additive Manufacturing Scheduling Problems (AMSPs) for producing metal parts. First, two mathematical formulations are proposed to enable the use of commercial solvers to optimize small- and medium-sized AMSPs. Second, a highly competitive solution algorithm called Tweaked Iterative Beam Search (TIBS) is developed to find (near-) optimal solutions to industry-scale problems. A total of 225 instances of various workloads are considered for numerical experiments, and the algorithm’s performance is evaluated, comparing it with the baselines. In 165 small and medium-sized instances, TIBS yielded 71 optimal solutions and 106 best-found solutions. For large-scale cases, all of the best-found solutions were obtained by TIBS. The statistical results support the significance of the outcomes in the optimization performance.

{"title":"Production scheduling of additively manufactured metal parts","authors":"Kuo-Ching Ying , Shih-Wei Lin , Pourya Pourhejazy , Fei-Huan Lee","doi":"10.1016/j.cirpj.2025.01.005","DOIUrl":"10.1016/j.cirpj.2025.01.005","url":null,"abstract":"<div><div>The production of metal products is one of the main areas where supply chains benefit from adopting additive manufacturing (AM). Optimizing the production process facilitates the widespread adoption of AM by improving know-how and reducing costs. This study offers a twofold contribution to facilitate the implementation of Additive Manufacturing Scheduling Problems (AMSPs) for producing metal parts. First, two mathematical formulations are proposed to enable the use of commercial solvers to optimize small- and medium-sized AMSPs. Second, a highly competitive solution algorithm called Tweaked Iterative Beam Search (TIBS) is developed to find (near-) optimal solutions to industry-scale problems. A total of 225 instances of various workloads are considered for numerical experiments, and the algorithm’s performance is evaluated, comparing it with the baselines. In 165 small and medium-sized instances, TIBS yielded 71 optimal solutions and 106 best-found solutions. For large-scale cases, all of the best-found solutions were obtained by TIBS. The statistical results support the significance of the outcomes in the optimization performance.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"57 ","pages":"Pages 100-115"},"PeriodicalIF":4.6,"publicationDate":"2025-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143175564","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Explanation of micro lead generation in external cylindrical plunge grinding of radial shaft sealing counterfaces

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-01-18 DOI: 10.1016/j.cirpj.2025.01.001

Jannik Röttger , Matthias Baumann , Frank Bauer , Peter Breuer , Thomas Bergs

This article examines the generation of micro lead during cylindrical plunge grinding of sealing counterfaces for rotary shaft seals. Micro lead can cause fluid leakage through the sealing contact, impacting sealing performance. Preliminary investigations indicate that dressing parameters influence micro lead formation. This publication presents new insights into this phenomenon, aiming to enhance industrial sealing reliability by optimizing sealing counterfaces for demanding applications, such as E-powertrains with high sliding speeds and temperatures. The presented findings underscore the value of using specifically optimized grinding and dressing parameters for the manufacturing of sealing counterfaces.

引用次数: 0

The wear analysis and life prediction of Cr12MoV alloy steel hammer dies during the radial forging process

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-01-16 DOI: 10.1016/j.cirpj.2025.01.002

Chenxi Bao, Yuzhao Yang, Cheng Xu

Radial forging is widely utilized in defense, aerospace, and automotive industries. However, understanding of hammer die wear during radial forging traditionally relies heavily on practical experience and lacks detailed research. This paper proposed a method for predicting hammer die failure during radial forging by using finite element simulations combined with the Archard wear model. The feasibility of this method was validated through profilometer measurements and scanning electron microscopy (SEM) observations of the worn hammer dies obtained from practical production. Through the mutual validation of simulations and experiments, the study found that when the hammer die material is specially treated Cr12MoV alloy steel, under the investigated operating conditions, the maximum surface wear of the hammer die exceeded 0.4 mm after approximately 13 cumulative hours of operation. This wear significantly affected the formation of the internal profile of the workpiece, at which point the hammer die was considered to have failed. The study deepens the understanding of the details of hammer die wear in the radial forging process and fills a gap in the prediction of hammer die failure during this process.

{"title":"The wear analysis and life prediction of Cr12MoV alloy steel hammer dies during the radial forging process","authors":"Chenxi Bao, Yuzhao Yang, Cheng Xu","doi":"10.1016/j.cirpj.2025.01.002","DOIUrl":"10.1016/j.cirpj.2025.01.002","url":null,"abstract":"<div><div>Radial forging is widely utilized in defense, aerospace, and automotive industries. However, understanding of hammer die wear during radial forging traditionally relies heavily on practical experience and lacks detailed research. This paper proposed a method for predicting hammer die failure during radial forging by using finite element simulations combined with the Archard wear model. The feasibility of this method was validated through profilometer measurements and scanning electron microscopy (SEM) observations of the worn hammer dies obtained from practical production. Through the mutual validation of simulations and experiments, the study found that when the hammer die material is specially treated Cr12MoV alloy steel, under the investigated operating conditions, the maximum surface wear of the hammer die exceeded 0.4 mm after approximately 13 cumulative hours of operation. This wear significantly affected the formation of the internal profile of the workpiece, at which point the hammer die was considered to have failed. The study deepens the understanding of the details of hammer die wear in the radial forging process and fills a gap in the prediction of hammer die failure during this process.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"57 ","pages":"Pages 63-77"},"PeriodicalIF":4.6,"publicationDate":"2025-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143175561","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}

引用次数: 0

Arc length–angle space-based overlap-free asymmetric corner smoothing method for five-axis toolpaths

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-01-08 DOI: 10.1016/j.cirpj.2024.12.009

Haiming Zhang , Jianzhong Yang , Song Gao , Wanqiang Zhu , Chenglei Zhang

Smoothing of linear toolpaths is critical to ensure quality and efficiency in computer numerical control (CNC) machining, particularly in 5-axis machining. However, existing corner smoothing methods often impose overly restrictive constraints on the transition lengths at corners, increasing curvature extremes and reducing the feedrate. To address this issue, this paper presents a five-axis toolpath asymmetric corner smoothing method based on the arc length–angle space. First, an arc length–angle space analysis method is introduced that can synchronize the tool tip position and tool orientation, decoupling the tool tip position and tool orientation smoothing processes. The tool tip position is smoothed with an asymmetric Pythagorean-hodograph (PH) curve in the workpiece coordinate system, whereas the tool orientation is smoothed with an asymmetric B-spline curve in the arc length–angle space. Then, to prevent overlap of adjacent transition curves, transition length adjustment strategies in the workpiece coordinate system and arc length–angle space are proposed to improve the corner feedrate within the set approximate error range. The simulation and machining experiment results show that, compared with existing asymmetric smoothing methods, the proposed method generates smoother toolpaths and achieves higher machining efficiency.

{"title":"Arc length–angle space-based overlap-free asymmetric corner smoothing method for five-axis toolpaths","authors":"Haiming Zhang , Jianzhong Yang , Song Gao , Wanqiang Zhu , Chenglei Zhang","doi":"10.1016/j.cirpj.2024.12.009","DOIUrl":"10.1016/j.cirpj.2024.12.009","url":null,"abstract":"<div><div>Smoothing of linear toolpaths is critical to ensure quality and efficiency in computer numerical control (CNC) machining, particularly in 5-axis machining. However, existing corner smoothing methods often impose overly restrictive constraints on the transition lengths at corners, increasing curvature extremes and reducing the feedrate. To address this issue, this paper presents a five-axis toolpath asymmetric corner smoothing method based on the arc length–angle space. First, an arc length–angle space analysis method is introduced that can synchronize the tool tip position and tool orientation, decoupling the tool tip position and tool orientation smoothing processes. The tool tip position is smoothed with an asymmetric Pythagorean-hodograph (PH) curve in the workpiece coordinate system, whereas the tool orientation is smoothed with an asymmetric B-spline curve in the arc length–angle space. Then, to prevent overlap of adjacent transition curves, transition length adjustment strategies in the workpiece coordinate system and arc length–angle space are proposed to improve the corner feedrate within the set approximate error range. The simulation and machining experiment results show that, compared with existing asymmetric smoothing methods, the proposed method generates smoother toolpaths and achieves higher machining efficiency.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"57 ","pages":"Pages 42-62"},"PeriodicalIF":4.6,"publicationDate":"2025-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174974","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}

引用次数: 0

Precise modeling of cutting forces based on domain adaptation extreme learning machine under small sample conditions

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-12-31 DOI: 10.1016/j.cirpj.2024.12.005

Shaonan Zhang , Liangshan Xiong

Given the high cost and complexity associated with acquiring a large number of experimental data of cutting forces, coupled with the challenges of overfitting and weak generalization in machine learning models for cutting forces prediction under small sample conditions, we propose two methods that employ the domain adaptation extreme learning machine (DAELM) algorithms to establish precise prediction models of cutting forces in small sample scenarios. In these methods, the large sample theoretical dataset of cutting forces calculated by parallel-sided shear zone model is used as the source domain dataset, while the small sample experimental dataset of cutting forces obtained by metal cutting experiments serves as the target domain dataset, and the cutting forces prediction models based on transfer learning are established employing DAELM algorithms. Applying these methods, precise prediction models of cutting forces in orthogonal cutting of 6061-T6 aluminum alloy have been established. Compared to the cutting force prediction models established using traditional neural network algorithms, those established using the proposed methods exhibit higher prediction precision and stronger generalization ability, even when only a small sample experimental dataset of cutting forces is available. The research findings can be applied to the transfer learning-based precise modeling of other continuously varying physical quantities in metal cutting processes under small sample conditions.

{"title":"Precise modeling of cutting forces based on domain adaptation extreme learning machine under small sample conditions","authors":"Shaonan Zhang , Liangshan Xiong","doi":"10.1016/j.cirpj.2024.12.005","DOIUrl":"10.1016/j.cirpj.2024.12.005","url":null,"abstract":"<div><div>Given the high cost and complexity associated with acquiring a large number of experimental data of cutting forces, coupled with the challenges of overfitting and weak generalization in machine learning models for cutting forces prediction under small sample conditions, we propose two methods that employ the domain adaptation extreme learning machine (DAELM) algorithms to establish precise prediction models of cutting forces in small sample scenarios. In these methods, the large sample theoretical dataset of cutting forces calculated by parallel-sided shear zone model is used as the source domain dataset, while the small sample experimental dataset of cutting forces obtained by metal cutting experiments serves as the target domain dataset, and the cutting forces prediction models based on transfer learning are established employing DAELM algorithms. Applying these methods, precise prediction models of cutting forces in orthogonal cutting of 6061-T6 aluminum alloy have been established. Compared to the cutting force prediction models established using traditional neural network algorithms, those established using the proposed methods exhibit higher prediction precision and stronger generalization ability, even when only a small sample experimental dataset of cutting forces is available. The research findings can be applied to the transfer learning-based precise modeling of other continuously varying physical quantities in metal cutting processes under small sample conditions.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"57 ","pages":"Pages 32-41"},"PeriodicalIF":4.6,"publicationDate":"2024-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174976","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}

引用次数: 0

Effect of forming parameters on the mechanical properties of clinched joint with rectangle punch

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-12-27 DOI: 10.1016/j.cirpj.2024.12.008

Chao Chen , Yuxin Yin , Yishen Chen , Xiangkun Ran

The emergence of advanced lightweight materials has not only provided more options for industrial lightweighting, but also imposes higher demands on joining technologies. The clinching process with rectangle punch (CRP) performs well in joining steel or other materials with poor plasticity. In the present paper, AA5182-O sheets were chosen as the research material. The microscopic mechanisms involved in the creation of clinched joints through CRP were examined. An in-depth investigation into the influence of varying forming force, forming speed, and punching angle on the shear strength and failure modes of these joints was conducted. In conclusion, enhancing the forming force positively impacts the shear strength. The failure mode transitions from the separation failure mode to the neck fracture mode. At a forming force of 35 kN, the peak shear strength achieved was 2324 N. The forming speed exhibited minimal influence on the failure mechanism. The orientation of the joint's longer side relative to the shear force direction significantly affects the failure mechanism, when positioned perpendicularly, the shear strength reached the maximum, which was approximately 1.68 times greater compared to a parallel orientation. During the failure process, the interlocking region was subjected to shear force before the neck region and fractured first.

{"title":"Effect of forming parameters on the mechanical properties of clinched joint with rectangle punch","authors":"Chao Chen , Yuxin Yin , Yishen Chen , Xiangkun Ran","doi":"10.1016/j.cirpj.2024.12.008","DOIUrl":"10.1016/j.cirpj.2024.12.008","url":null,"abstract":"<div><div>The emergence of advanced lightweight materials has not only provided more options for industrial lightweighting, but also imposes higher demands on joining technologies. The clinching process with rectangle punch (CRP) performs well in joining steel or other materials with poor plasticity. In the present paper, AA5182-O sheets were chosen as the research material. The microscopic mechanisms involved in the creation of clinched joints through CRP were examined. An in-depth investigation into the influence of varying forming force, forming speed, and punching angle on the shear strength and failure modes of these joints was conducted. In conclusion, enhancing the forming force positively impacts the shear strength. The failure mode transitions from the separation failure mode to the neck fracture mode. At a forming force of 35 kN, the peak shear strength achieved was 2324 N. The forming speed exhibited minimal influence on the failure mechanism. The orientation of the joint's longer side relative to the shear force direction significantly affects the failure mechanism, when positioned perpendicularly, the shear strength reached the maximum, which was approximately 1.68 times greater compared to a parallel orientation. During the failure process, the interlocking region was subjected to shear force before the neck region and fractured first.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"57 ","pages":"Pages 1-13"},"PeriodicalIF":4.6,"publicationDate":"2024-12-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174977","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}

引用次数: 0

A microstructure-integrated acoustoplastic constitutive model for ultrasonic-assisted machining of Ti6Al4V alloy

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-12-27 DOI: 10.1016/j.cirpj.2024.12.007

H. Bakhshan , E. Oñate , J.M Carbonell

The ultrasonic-assisted machining (UAM) technology, compared to conventional machining (CM), has been proven to be an effective method for machining the difficult-to-cut Ti6Al4V alloy (TC4). In the UAM process, the evolution mechanism of microstructure and hardness directly influences the material behavior and consequently, mechanical response, which remains unrevealed from a computational perspective. To address this, in this study, we present a developed modeling technique that combines the Particle Finite Element Method (PFEM) with incremental homogeneous field distributions in a coupled manner to effectively predict the macro and micro response of the material in both CM and UAM processes. First, the evolution of microstructural parameters, including immobile dislocation density (IDD) and mobile dislocation density (MDD), dynamic recrystallization (DRx) grain size, and hardness, is incrementally developed and incorporated into the PFEM using internal state variables. The Johnson–Mehl–Avrami–Kolmogorov (JMAK) model and Hall–Petch equation are employed for predicting grain size and hardness, respectively. Second, A microstructure-integrated acoustoplastic constitutive model is developed based on a modified Johnson–Cook (JC) model and average grain size (AGS) predictions dependent on ultrasonic vibration (UV) parameters. The proposed model is embedded into the PFEM to conduct a thermo-mechanical analysis capable of capturing the TC4 response, particularly in terms of serrated chip formation during CM and UAM processes. The model’s validity is checked through comparison with available experimental results in terms of chip shapes. Lastly, the predicted AGS and hardness in serrated chips and machined surface are compared with experimental data, showing good agreement. This suggests that the proposed acoustoplastic constitutive model, coupled with microstructure and UV parameters, can reliably analyze the CM and UAM processes of the TC4.

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