CIRP Journal of Manufacturing Science and Technology最新文献_第2页

Development of an innovative, self-adjusting fixturing system with functional independence based on graph theory 基于图论的功能独立自调节夹具系统的开发

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-22 DOI: 10.1016/j.cirpj.2025.12.007

Cristhian Chaves Arroyo , Iván Darío Ruiz , Jose I. Garcia-Melo

Driven by the need to respond effectively to the dynamic demands of globalized markets, industrial organizations are continuously improving their manufacturing processes. In this context, manufacturing systems require flexible workpiece fixturing devices that ensure both effective and efficient operational repeatability to accommodate the growing trend of mass customization. This paper presents an innovative solution to meet the requirements of a self-adjusting fixturing system characterized by functional independence, defined here as the decoupling of key operations (such as thickness adjustment and clamping force) to enhance control and performance. To achieve this, the proposed approach integrates several theories and tools, including mechanism theory, graph theory, axiomatic design, and ergonomics. The result is a functional prototype that demonstrates the strengths of the proposed design approach in defining solutions with complex topologies for workpiece fixturing applications. This novel design offers significant practical benefits, including drastically reduced setup times and a pre-settable, independent clamping force. The methodology and resulting system provide a robust solution for flexible manufacturing, particularly in mass customization and future automated (Industry 4.0) environments.

在需要有效应对全球化市场的动态需求的驱动下，工业组织正在不断改进其制造工艺。在这种情况下，制造系统需要灵活的工件固定装置，以确保有效和高效的操作重复性，以适应日益增长的大规模定制趋势。本文提出了一种创新的解决方案，以满足具有功能独立性的自调节夹具系统的要求，这里定义为关键操作（如厚度调整和夹紧力）的解耦，以增强控制和性能。为了实现这一目标，所提出的方法集成了几种理论和工具，包括机制理论、图论、公理设计和人体工程学。结果是一个功能原型，展示了所提出的设计方法在定义具有复杂拓扑的工件夹具应用解决方案方面的优势。这种新颖的设计提供了显著的实际好处，包括大幅减少安装时间和预先设定的独立夹紧力。该方法和最终系统为柔性制造提供了强大的解决方案，特别是在大规模定制和未来自动化（工业4.0）环境中。

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引用次数: 0

Mudguard stamping springback control for agricultural tractors: Collaborative multi-strategy approach and experimental verification 农用拖拉机挡泥板冲压回弹控制：协同多策略方法及实验验证

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-19 DOI: 10.1016/j.cirpj.2025.12.008

Shuo Wang , Hongchao Wang , Rutie Zeng , Lin Wan , Gang Che

To effectively control the springback of agricultural tractor mudguards, this paper proposes an optimized design framework for springback control. The framework centers on stress path control and geometric reverse compensation, integrating process parameter optimization, theoretical modeling, auxiliary structure design, and geometric reverse mold compensation. This approach transitions from a single-method strategy to a combined approach of “process parameter control – drawbead setting – geometric reverse compensation”. The results indicate a significant correlation between the thickness, blank holder force, stamping speed, friction coefficient, and die clearance with the springback amount. The semi-analytical model and response surface model developed have coefficients of determination of 0.921 and 0.917, respectively. A complex non-linear relationship exists between each parameter and the springback, with distinct mathematical variation curves observed. The primary and secondary effects of the parameters are ranked as follows: blank holder force, die clearance, thickness, friction coefficient, and stamping speed. By employing the “process parameter control – drawbead setting – geometric reverse compensation” strategy, the springback can be controlled to 5.37 °. Moreover, experimental validation yields a springback of 5.14 °, which results in a 0.23 °. This study provides a solid theoretical foundation and reliable numerical basis for the practical production and processing of mudguards.

为了有效控制农用拖拉机挡泥板的回弹，提出了一种优化的回弹控制设计框架。该框架以应力路径控制和几何反向补偿为核心，集工艺参数优化、理论建模、辅助结构设计和几何反向补偿于一体。该方法由单一方法转变为“工艺参数控制-拉延头设定-几何反向补偿”的组合方法。结果表明，厚度、压边力、冲压速度、摩擦系数和模具间隙与回弹量有显著的相关性。建立的半解析模型和响应面模型的决定系数分别为0.921和0.917。各参数与回弹之间存在复杂的非线性关系，具有明显的数学变化曲线。各参数对压边力、模具间隙、厚度、摩擦系数、冲压速度的主要影响和次要影响依次为：压边力、模具间隙、冲压速度。采用“工艺参数控制-拉延头设定-几何反向补偿”策略，可将回弹控制在5.37°。此外，实验验证产生5.14°的回弹，其结果为0.23°。该研究为挡泥板的实际生产加工提供了坚实的理论基础和可靠的数值依据。

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引用次数: 0

Research on the deformation behavior and microstructure characteristics of 2024 aluminum alloy spun parts in die-less spinning process using ball-crown-shape rollers 采用球冠形滚轮无模旋压2024铝合金旋压件的变形行为和显微组织特征研究

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-17 DOI: 10.1016/j.cirpj.2025.12.009

Yongping Shen , Yijie Chen , Zhen Jia , Guangrui Wang

Die-less spinning can greatly enhance the flexibility of spinning technology. Nevertheless, the significant wall thinning under variable taper angle conditions severely limits its application, replacing the conventional roller with a ball-crown-shaped roller (BCSR) can effectively suppressing the wall thinning. However, the mechanisms underlying this suppression are unclear and warrant detailed investigation. Microstructural characterization is an effective means to elucidate the mechanism of wall thinning suppression. Therefore, in this study, spinning experiments were conducted using multiple BCSRs and a conventional roller, followed by a systematic analysis of the mechanical properties and microstructure of the workpiece. Electron backscattered diffraction analysis was employed to reveal the origin of these differences at the microscopic level. The results showed that grains in BCSR-spun workpieces retained equiaxed morphology similar to that of the original blank, whereas those subjected to conventional roller spinning exhibited larger elongation. Among the BCSR conditions, rollers with larger radii produced larger grain sizes and lower percentages of low-angle grain boundaries, reflecting reduced deformation. The geometrically necessary dislocation density and tensile strength of the BCSR-spun workpieces were close to those of the original blank. The wall thinning suppression mechanism was clarified: conventional roller spinning induces shear-dominated deformation, whereas BCSR spinning primarily involves bending deformation. The greater circumferential compressive stress generated during BCSR spinning effectively inhibited wall thinning. Furthermore, increasing the BCSR radius reduced sheet bending and tensile stress in the feed direction, while a larger roller–blank contact area increased resistance to deformation and friction of the material, thereby suppressing wall thinning.

无模纺丝可大大提高纺丝工艺的灵活性。然而，变锥角条件下明显的壁厚变薄严重限制了其应用，用球冠状滚子（BCSR）代替传统滚子可以有效地抑制壁厚变薄。然而，这种抑制的机制尚不清楚，需要进行详细的调查。微观结构表征是阐明管壁减薄抑制机理的有效手段。因此，在本研究中，采用多个BCSRs和一个常规辊进行纺丝实验，并对工件的力学性能和微观结构进行系统分析。电子背散射衍射分析在微观水平上揭示了这些差异的来源。结果表明，bcsr纺丝后的工件晶粒保持了与原始毛坯相似的等轴形态，而传统滚柱纺丝后的工件晶粒伸长率更高。在BCSR条件下，半径越大的辊产生的晶粒尺寸越大，低角度晶界的百分比越低，反映了变形的减少。坯料的几何必要位错密度和抗拉强度与原坯料接近。阐明了管壁减薄抑制机理：传统滚柱纺纱引起剪切为主的变形，而BCSR纺纱主要引起弯曲变形。在BCSR旋转过程中产生的较大的周向压应力有效地抑制了壁薄。此外，增加BCSR半径可以降低板材在进料方向上的弯曲和拉应力，而较大的辊坯接触面积增加了材料的变形和摩擦阻力，从而抑制了壁厚变薄。

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引用次数: 0

Integrated framework for in-process modal analysis and tool–workpiece engagement detection 用于过程中模态分析和工具-工件接合检测的集成框架

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-16 DOI: 10.1016/j.cirpj.2025.12.010

Samet Can Kaçan, Hakan Çalışkan

This paper presents an Extended Kalman Filter (EKF)-based real-time methodology for in-process modal identification and tool–workpiece engagement detection in milling operations. Unlike conventional offline Experimental Modal Analysis (EMA) and Operational Modal Analysis (OMA) methods, the proposed approach enables online tracking of time-varying modal parameters without requiring external excitation and force measurement. It is proposed to utilize the acceleration measurements occurring between two consecutive tooth-workpiece engagements, for that purpose an EKF, based on the free vibration response model is constructed. The angular tool position is not measured, to identify the onset of free vibration, a robust engagement detection algorithm is developed, which remains effective under spindle speed variations and geometric inaccuracies. The complete framework consists of three stages: (i) recursive estimation of dominant modal parameters — natural frequency, damping ratio, and amplitude — using the EKF; (ii) adaptive engagement detection through thresholding of the mean absolute scaled error (MASE); and (iii) refinement of the estimated modal parameters via median and Kalman filtering to suppress Bernoulli and Gaussian noise. The proposed method is experimentally validated on a thin wall cantilever workpiece during end-milling where results are compared with conventional hammer-test EMA results. The identified modal parameters closely match the EMA results demonstrating the method’s potential in monitoring machining processes.

本文提出了一种基于扩展卡尔曼滤波（EKF）的铣削加工过程中模态识别和刀具-工件啮合检测的实时方法。与传统的离线实验模态分析（EMA）和运行模态分析（OMA）方法不同，该方法能够在线跟踪时变模态参数，而无需外部激励和力测量。提出了利用连续两个齿与工件啮合之间的加速度测量，为此建立了基于自由振动响应模型的EKF。在不测量刀具角度位置的情况下，为了识别自由振动的开始，开发了一种鲁棒的啮合检测算法，该算法在主轴转速变化和几何不精度下仍然有效。完整的框架包括三个阶段：(i)使用EKF递归估计主模态参数-固有频率，阻尼比和振幅；（ii）通过对平均绝对比例误差（MASE）进行阈值化的自适应交战检测；（iii）通过中值滤波和卡尔曼滤波对估计的模态参数进行细化，以抑制伯努利和高斯噪声。在薄壁悬臂工件端铣削过程中对该方法进行了实验验证，并与常规锤击试验结果进行了比较。识别出的模态参数与EMA结果非常吻合，证明了该方法在机械加工过程监控中的潜力。

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引用次数: 0

Evaluation of nanoparticle exposure during Wire Arc Additive Manufacturing (WAAM) processes 电弧增材制造（WAAM）过程中纳米颗粒暴露的评价

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-15 DOI: 10.1016/j.cirpj.2025.12.006

Roberta Pernetti , Noemi Paulin , Akshay Ashok Benni , Francesca Paradiso , Barbara Previtali , Enrico Oddone

Wire Arc Additive Manufacturing (WAAM) is an advanced layer-by-layer metal printing technology that builds three-dimensional components layer by layer by melting a metal wire using an electric arc. While it is well established that high-temperature metal melting results in the emission of metal and metal oxide nanoparticles, limited data is currently available for WAAM due to the relative novelty of the process.

This study investigates nanoparticle emissions in a laboratory environment where the WAAM system is enclosed within a closed box during the production phase. Measurements were conducted across four processes using AlSi5 and S700 feedstocks under both standard and non-ventilated conditions. The results show a significant release of incidental nanoparticles in all the processes during the arc activation, with average concentrations ranging from 10⁵ to 10⁶ n/cm³ and diameters between 15 and 22 nm. Concentrations declined rapidly during inter-cooling intervals and after the process concluded.

Moreover, daily exposure assessment scenarios demonstrate that, if the WAAM system is fully enclosed during production, average exposure levels remain below the available reference values (i.e. 20,000 and 40,000 n/cm³ for high and low-density materials respectively). In contrast, when operators remain close to the WAAM system throughout during the production phase, the exposure levels can exceed the reference values by 12 % to 1.8 times for S700 and by 3–5 times for AlSi5, depending on the distance.

These findings highlight the critical importance of properly installing the WAAM system to ensure effective control of operator exposure to incidentally released nanoparticles.

电弧增材制造（WAAM）是一种先进的逐层金属打印技术，通过电弧熔化金属丝，逐层构建三维部件。虽然已经确定高温金属熔化会导致金属和金属氧化物纳米颗粒的发射，但由于该工艺相对新颖，目前可获得的WAAM数据有限。本研究在实验室环境中调查纳米颗粒的排放，在生产阶段，WAAM系统被封闭在一个封闭的盒子里。在标准和非通风条件下，使用AlSi5和S700原料进行了四个过程的测量。结果表明，在电弧活化的所有过程中，偶然的纳米颗粒都有明显的释放，平均浓度在105 ~ 106 n/cm3之间，直径在15 ~ 22 nm之间。在中间冷却间隔和过程结束后，浓度迅速下降。此外，每日暴露评估情景表明，如果WAAM系统在生产过程中完全封闭，平均暴露水平仍低于可用的参考值（即高密度和低密度材料分别为20,000和40,000 n/cm3）。相比之下，当作业人员在整个生产阶段都靠近WAAM系统时，S700的暴露水平可能超过参考值12 %至1.8倍，AlSi5的暴露水平可能超过参考值3-5 倍，具体取决于距离。这些发现强调了正确安装WAAM系统以确保有效控制操作人员接触偶然释放的纳米颗粒的重要性。

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引用次数: 0

Effect of layer thickness on the microstructure and machinability of AlSi7Mg processed by laser powder bed fusion 层厚对激光粉末床熔合AlSi7Mg显微组织和可加工性的影响

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-13 DOI: 10.1016/j.cirpj.2025.12.005

Edoardo Ghinatti , Toushiqul Islam , Shuaihang Pan , Rachele Bertolini , Stefania Bruschi

This study examines the influence of laser powder bed fusion (LPBF) layer thickness on the machinability of AlSi7Mg aluminum alloy. Samples fabricated with layer thicknesses of 20, 25, and 30 µm were heat-treated and then turned under fixed cutting parameters. The machinability was assessed in terms of cutting forces, surface roughness, and surface defects. Results showed that decreasing the layer thickness increased cutting forces and surface roughness, with the samples produced with a 20 µm layer thickness exhibiting the poorest machinability. The explanation of the lower machinability with decreasing layer thickness was associated with the microstructural and mechanical features characterizing the samples. At lower layer thickness, the microstructure is more anisotropic and ductile, leading to higher cutting forces and rougher surfaces. Contrarily, at greater layer thicknesses, the more uniform and less tough microstructure results in lower cutting forces and smoother surfaces. The presence of different Fe-rich intermetallics at different layer thicknesses also influences the morphology of the defects found on the machined surfaces. The findings highlight the importance of optimizing layer thickness to enhance the machinability of LPBF AlSi7Mg parts.

研究了激光粉末床熔合（LPBF）层厚度对AlSi7Mg铝合金可加工性的影响。制备层厚度分别为20、25和30 µm的样品进行热处理，然后在固定的切削参数下进行车削。可加工性是根据切削力、表面粗糙度和表面缺陷来评估的。结果表明，随着层厚的减小，切削力和表面粗糙度增大，当层厚为20 µm时，切削性能最差。随着层厚的减小，可加工性降低的原因与样品的显微组织和力学特征有关。在较低的层厚下，微观组织具有较强的各向异性和延展性，导致更高的切削力和更粗糙的表面。相反，在更大的层厚下，更均匀和更少韧性的微观组织导致更低的切削力和更光滑的表面。不同层厚度的富铁金属间化合物的存在也会影响加工表面缺陷的形貌。研究结果强调了优化层厚对提高LPBF AlSi7Mg零件可加工性的重要性。

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引用次数: 0

Reviewers for CIRP journal of manufacturing science and technology, 2025 《制造科学与技术》，2025年审稿人

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-11 DOI: 10.1016/j.cirpj.2025.12.003

Yusuf Altintas (Editor-in-Chief)

引用次数: 0

Enhanced tribological behavior and fatigue life of Inconel 718 via combined nanofluid internal cooling and self-lubricating grinding 纳米流体内部冷却与自润滑磨削相结合，提高了Inconel 718的摩擦学性能和疲劳寿命

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-09 DOI: 10.1016/j.cirpj.2025.12.004

Ruitao Peng , Xiang Chen , Linfeng Zhao , Jinchi Yao , Xiaofang Huang , Wentao Chen

Superalloys such as Inconel 718 suffer severe thermo-mechanical damage during grinding due to inherent low thermal conductivity and high interfacial friction, critically degrading surface integrity and fatigue life. To address this, an integrated tribo-regulation strategy combining internal-cooling wheels, self-lubricating abrasive rings, and water-based BNNs/MWCNTs Composite nanofluids is proposed. The geometric shape of the flow channel (with a 15° nozzle angle) was optimized through computational fluid dynamics (CFD), which resulted in an increase in the peak velocity of the coolant outlet. Tribological characterization confirmed that the nanofluid reduced the friction coefficient by 40.6 % versus conventional coolant, while synergistic self-lubrication further lowered it to 0.127. Experimentally, this strategy suppressed grinding temperature by up to 34.3 % and surface roughness by 37.6 %. It also reduced work hardening by 11.2 % while enhancing residual compressive stress by 41.6 %. Crucially, the "bearing-like" rolling effect of BNNs/MWCNTs nanoparticles and continuous lubricating films from self-lubrication minimized ploughing and adhesion. Compared with conventional internal-cooling grinding, the low-cycle fatigue life increased to 4026 cycles—a 127.1 % improvement—attributed to stress concentration suppression and crack propagation delay. This integrated nanofluid internal-cooling self-lubricating grinding (INISG) strategy is highly recommended for high-integrity machining of aerospace superalloys, offering a sustainable pathway for enhancing component reliability and service life.

高温合金，如Inconel 718，由于其固有的低导热系数和高界面摩擦，在磨削过程中会遭受严重的热机械损伤，严重降低表面完整性和疲劳寿命。为了解决这一问题，研究人员提出了一种综合摩擦调节策略，该策略结合了内冷却轮、自润滑磨料环和水基BNNs/MWCNTs复合纳米流体。通过计算流体力学（CFD）对喷嘴角为15°的流道几何形状进行优化，使冷却剂出口的峰值速度有所提高。摩擦学特性证实，与传统冷却剂相比，纳米流体将摩擦系数降低了40.6 %，而协同自润滑进一步将摩擦系数降低至0.127。实验表明，该策略可使磨削温度降低34.3% %，表面粗糙度降低37.6% %。它还降低了11. %的加工硬化，同时提高了41.6 %的残余压应力。至关重要的是，BNNs/MWCNTs纳米颗粒的“轴承状”滚动效应和自润滑的连续润滑膜最大限度地减少了犁地和粘附。与传统内冷磨削相比，由于应力集中抑制和裂纹扩展延迟，低周疲劳寿命提高到4026次，提高了127.1 %。这种集成的纳米流体内冷自润滑磨削（INISG）策略被推荐用于航空航天高温合金的高完整性加工，为提高部件的可靠性和使用寿命提供了可持续的途径。

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引用次数: 0

Metrological validation of a deep learning pipeline for in-line detection and dimensional quantification of three-dimensional surface defects 三维表面缺陷在线检测和尺寸量化的深度学习管道的计量验证

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-08 DOI: 10.1016/j.cirpj.2025.12.002

Sofia Catalucci, Enrico Savio

Defect detection is critical in manufacturing processes such as casting, machining, and additive manufacturing, where imperfections can impair part functionality and reliability. This work proposes a deep learning-based methodology for the detection and dimensional inspection of three-dimensional surface defects. The approach integrates deep learning trained on pre-labelled data and applied to two-dimensional deviation maps derived from laser-based measurements, and a skeletonization algorithm to estimate defect dimensions. Accuracy is ensured by metrological validation using reference measurements from a multisensor coordinate measuring machine. Applied to die-cast components, the framework demonstrates robust performance, offering a reliable tool for integration into real-world quality control workflows.

缺陷检测在铸造、机械加工和增材制造等制造过程中至关重要，在这些过程中，缺陷会损害零件的功能和可靠性。这项工作提出了一种基于深度学习的三维表面缺陷检测和尺寸检测方法。该方法集成了预先标记数据训练的深度学习，并应用于基于激光测量的二维偏差图，以及用于估计缺陷尺寸的骨架化算法。通过使用多传感器坐标测量机的参考测量进行计量验证，确保精度。应用于压铸组件，该框架展示了强大的性能，为集成到现实世界的质量控制工作流程提供了可靠的工具。

引用次数: 0

Towards sustainability in the aerospace industry: Environmental impact of different drilling strategies for CFRP/Aluminium stacks 航空航天工业的可持续发展：CFRP/铝堆不同钻孔策略的环境影响

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-05 DOI: 10.1016/j.cirpj.2025.12.001

Martina Panico , Ersilia Cozzolino , Antonello Astarita , Eva Begemann , Andreas Gebhardt , Luca Boccarusso

In the last decade improving the sustainability of manufacturing processes has become a primary objective to tackle the goals for sustainable development as defined by UN. In this context, the Life Cycle Assessment (LCA) is finding increasing use as a method to measure the environmental impacts of processes and as a tool to support decisions when a choice between different processing routes is required. The present study lies in this context: a detailed LCA analysis has been carried out to compare the environmental footprint of different drilling strategies, the quality of the drilled holes has also been considered to provide reliable guidelines to people interested in drilling operations. In particular, this study investigates the environmental impacts of different drilling strategies applied to CFRP/AA7075-T6 stacks, which are commonly used in structural aerospace assemblies. A cradle-to-gate LCA was performed to compare two main approaches: separate drilling of CFRP laminates and aluminium alloy sheets before their assembly, and one-shot drilling of pre-assembled stacks. A strength of this study, conversely to the others available in the literature, is that the analysis relies on experimental data for energy consumption, drilling forces and hole quality, enabling a high-fidelity environmental assessment. The results show that the drilling strategies significantly affect both the environmental indicators, process performance and hole quality, highlighting a trade-off between energy efficiency and hole characteristics. Findings offer new insight to guide sustainable decision-making in aerospace manufacturing.

在过去十年中，改善制造过程的可持续性已成为解决联合国确定的可持续发展目标的主要目标。在这种情况下，生命周期评估（LCA）越来越多地被用作测量过程对环境影响的方法，以及在需要在不同的加工路线之间进行选择时作为支持决策的工具。目前的研究就是在这样的背景下进行的：进行了详细的LCA分析，以比较不同钻井策略的环境足迹，也考虑了钻孔的质量，为对钻井作业感兴趣的人提供可靠的指导。特别是，本研究调查了CFRP/AA7075-T6叠层的不同钻井策略对环境的影响，这些叠层通常用于结构航空组件。进行了从起点到门的LCA，比较了两种主要方法：CFRP层压板和铝合金板在组装前分别钻孔，以及预组装堆栈的一次钻孔。与文献中的其他研究相反，本研究的优势在于，其分析依赖于能耗、钻井力和井眼质量的实验数据，从而实现高保真的环境评估。结果表明，钻井策略对环境指标、工艺性能和井眼质量都有显著影响，突出了能源效率和井眼特征之间的权衡。研究结果为指导航空航天制造业的可持续决策提供了新的见解。

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引用次数: 0