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Research on cutting force characteristics and parameter optimization of laser-ultrasonic composite milling of cemented carbide 激光-超声复合铣削硬质合金切削力特性及参数优化研究
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2025-12-27 DOI: 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.
硬质合金是一种超硬材料,具有高硬度和低断裂韧性。采用传统方法加工时,具有效率低、成本高、质量差的特点。为了提高硬质合金的超精密加工性能,提出了一种激光-超声复合铣削加工工艺。分析了超声振动的运动特性和激光预热特性,建立了铣削力理论模型,预测结果误差小于10 %。与常规铣削(CM)、超声辅助铣削(UAM)和激光辅助铣削(LAM)相比,LUCM的主铣削力(Fx)、径向力(Fy)和轴向力(Fz)值分别降低了23.49 % ~ 58.50 %、6.90 % ~ 39.79 %和13.07 % ~ 29.44 %。刀具寿命分别延长了91.63% %、44.65 %和29.46 %,表面粗糙度降低了33.05% %。根据响应面法(RSM)分析,当激光功率(LP)为345.775 W,激光束直径(LBD)为0.236 mm,距激光光斑中心距离(DFLSC)为0.059 mm,超声振幅(UA)为2.065μm时,优化后的Fx最小值为70.452 N。利用人工神经网络(ANN)对实验数据进行拟合和训练,结果表明,实验值与拟合值高度一致,误差小于±2。
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引用次数: 0
Numerical modeling of damage accumulation mechanism in ball burnishing with undefined ball motion of AA6061-T6 AA6061-T6未定义球运动抛光损伤累积机理数值模拟
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2025-12-27 DOI: 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 23, 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.
在抛光过程中,由于局部变形和球滚,材料处于复杂的应力状态,工件受到不同的应力分量。在这些加载条件下,材料进入塑性区,塑性应变的积累导致工件内部损伤的发展。多阶段过程的损伤预测具有一定的挑战性。本文采用有限元法和接触力学理论对过程进行了建模。由于目前国内外对抛光过程中损伤积累机理的研究较少,本文拟采用非线性模型研究抛光过程中的损伤积累机理和损伤预测。利用Abaqus软件中的VUSDFLD子程序定义损伤模型。研究了反向加载对损伤扩展的影响以及预测失效发生的准确性。变形力学表明应力状态发生了剧烈变化,这在损伤准则的定标中应予以考虑。因此,采用一种适合于抛光载荷的新试验对非线性模型进行校正。结果表明,采用非线性准则,选择损伤形成阈值为- 23,预测临界侵彻深度,误差为4.54%。阈值对起裂力矩和起裂位置的影响显著,其不明确导致临界侵彻深度预测误差达36.4%。用塑性应变来估计加工硬化。塑性应变沿厚度方向的变化与工件的硬度分布相对应。
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引用次数: 0
Friction stir lap welding of AA 2139 and AA 7075: Processing and sustainability analysis aa2139和aa7075搅拌摩擦搭接焊:工艺及可持续性分析
IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Pub Date : 2025-12-24 DOI: 10.1016/j.cirpj.2025.12.015
Vitantonio Esperto , Ersilia Cozzolino , Antonello Astarita , Pierpaolo Carlone , Felice Rubino
Friction Stir Welding (FSW) is increasingly adopted by industry to join difficult-to-weld materials thanks to its high energy efficiency and environmental sustainability. However, despite the extensive research, the studies on the sustainability of the process in correlation with the mechanical performance of the joints are still in the early stages. This study combines the analysis of energy consumption and mechanical properties in the FSW of dissimilar aluminum alloys, exploring different combinations of key process parameters. A gate-to-gate Life Cycle Assessment (LCA) was conducted to evaluate the environmental impact of the FSW process. From a sustainability standpoint, the optimal result was achieved using the highest travel speed (TS) of 270 mm/min in combination with a tool rotational speed (TRS) of 2000 rpm. Under these process conditions, reductions of up to 61 % in global warming potential (GWP), 62 % in total energy consumption, and 62 % in specific welding energy (SWE) were observed at the cost of approximately a 13 % reduction in flexural strength. As a result, power/energy, microhardness, microstructure, and flexural tests were incorporated into welding parameter maps to help in identifying minimum energy consumption and GWP points within the process constraints needed for maintaining good welding quality.
搅拌摩擦焊(FSW)由于其高能效和环境可持续性,越来越多地被工业应用于连接难焊材料。然而,尽管研究广泛,但对该过程的可持续性与节点力学性能的关系的研究仍处于早期阶段。本研究结合对不同铝合金搅拌搅拌能耗和力学性能的分析,探索关键工艺参数的不同组合。通过“门到门”生命周期评估(LCA)来评估FSW过程的环境影响。从可持续性的角度来看,当最高行程速度(TS)为270 mm/min,刀具转速(TRS)为2000 rpm时,获得了最佳结果。在这些工艺条件下,全球变暖潜能值(GWP)降低了61% %,总能耗降低了62% %,比焊接能量(SWE)降低了62% %,而弯曲强度降低了约13% %。因此,功率/能量、显微硬度、微观结构和弯曲测试被纳入焊接参数图,以帮助确定在保持良好焊接质量所需的工艺限制内的最小能耗和GWP点。
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引用次数: 0
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 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 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 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 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 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 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 Pub Date : 2025-12-11 DOI: 10.1016/j.cirpj.2025.12.003
Yusuf Altintas (Editor-in-Chief)
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引用次数: 0
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CIRP Journal of Manufacturing Science and Technology
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