CIRP Journal of Manufacturing Science and Technology最新文献_第3页

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

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2026-04-01 Epub 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

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

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2026-04-01 Epub 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

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

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2026-04-01 Epub 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

Comparative analysis of interfacial characteristics and jetting phenomena in explosive, vaporizing foil actuator, and laser impact welding 爆炸、汽化箔和激光冲击焊接中界面特性和喷射现象的对比分析

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2026-02-01 Epub Date: 2025-12-01 DOI: 10.1016/j.cirpj.2025.09.012

Taeseon Lee , Deepak Kumar , Anupam Vivek , Curtis Prothe , Glenn Daehn

This study compares three high-velocity impact welding techniques (explosive welding (EXW), vaporizing foil actuator welding (VFAW), and laser impact welding (LIW)), using AA1100-O flyers and AISI 1018 targets over flyer thicknesses of 0.07 mm-57.15 mm and impact velocities of 510 m/s-750 m/s. Photon Doppler velocimetry (PDV) quantified flyer kinematics, scanning electron microscopy (SEM) resolved interfacial morphology, and smoothed particle hydrodynamics (SPH) captured pressure wave propagation, collision-induced heating and jetting. Interfacial wavelengths spanned ∼6 µm (LIW), ∼37 µm (VFAW), to ∼2.9 mm (EXW). In EXW, wave size increased with flyer thickness (6.35→22.86 mm) despite decreasing velocity (750→400 m/s), indicating that flyer mass/kinetic energy can dominate over velocity alone. Melting layer width in EXW rose from ∼1.3 mm to ∼3.1 mm and correlated with thicker IMCs (∼3–5 µm → ∼20–30 µm) localized at wave crests, while troughs remained largely IMC-free. Across LIW→VFAW, peak interface pressures decreased (e.g., LIW ∼5.2 ×10⁷→2.64 ×10⁷ kPa, VFAW ∼1.23 ×10⁷→3.77 ×10⁶ kPa with increasing flyer thickness), producing longer wavelengths and broader but cooler thermal zones. Jetting exhibited a decoupling, quantity increased with flyer thickness/spot footprint (EXW > VFAW > LIW), whereas velocity tracked peak pressure (LIW > VFAW > EXW). Collectively, the results show that pressure-pulse duration and spatial distribution, not velocity alone govern interfacial waviness, thermal gradients, and jetting. The unified pressure-wave framework provides process design guidance, EXW for large, robust clads, VFAW for medium-thickness lightweight joints and LIW for fine-scale joining.

本研究比较了三种高速冲击焊接技术（爆炸焊接（EXW），汽化箔驱动器焊接（VFAW）和激光冲击焊接（LIW）），使用AA1100-O飞片和AISI 1018靶，飞片厚度为0.07 mm-57.15 mm，冲击速度为510 m/s-750 m/s。光子多普勒测速（PDV）量化了飞片的运动学，扫描电子显微镜（SEM）解析了界面形貌，平滑粒子流体动力学（SPH）捕获了压力波的传播、碰撞引起的加热和喷射。界面波长范围为~ 6 µm (LIW), ~ 37 µm (VFAW), ~ 2.9 mm （EXW）。在高流速下，尽管速度减小（750→400 m/s），但波浪尺寸随飞片厚度增大（6.35→22.86 mm），表明飞片质量/动能比速度单独起主导作用。EXW熔化层宽度从~ 1.3 mm上升到~ 3.1 mm，并与波峰处较厚的内压分布（~ 3-5 µm→~ 20-30 µm）相关，而波谷基本没有内压分布。在整个LIW→VFAW，峰值界面压力下降（例如，LIW ~ 5.2 ×10⁷→2.64 ×10⁷kPa, VFAW ~ 1.23 ×10⁷→3.77 ×10 26 kPa随着飞片厚度的增加），产生更长的波长和更宽但更冷的热区。喷射表现为不耦合，喷射量随飞片厚度/点足迹增加（EXW > VFAW >； LIW），而速度随峰值压力增加（LIW > VFAW >； EXW）。总的来说，结果表明压力脉冲持续时间和空间分布，而不是速度单独控制界面波度、热梯度和喷射。统一的压力波框架为工艺设计提供指导，EXW适用于大型、坚固的包层，VFAW适用于中厚轻质接头，LIW适用于精细连接。

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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 : 2026-02-01 Epub 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

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 : 2026-02-01 Epub 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

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 : 2026-02-01 Epub 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

Speed-controlled printing strategy for functionally graded TPMS structures: A process optimization perspective 功能梯度TPMS结构的速度控制印刷策略：工艺优化视角

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2026-02-01 Epub Date: 2025-11-29 DOI: 10.1016/j.cirpj.2025.11.010

Mohamed Chairi , Guido Di Bella , Gabriele Marabello , Roman Savin , Nikolay Yudin

This work introduces a novel, process-driven strategy for manufacturing functionally graded Triply Periodic Minimal Surface (TPMS) structures via fused filament fabrication, based on controlling local density through printhead speed modulation. Unlike conventional approaches that rely on geometric variation or toolpath complexity, this method maintains a constant slicing geometry while adjusting the printhead velocity to vary material deposition rate: slower speeds generate higher density, while faster speeds result in reduced material accumulation. Compared with uniform counterparts, the graded specimen reduced build time by ∼28 %. Moreover, for the same target density map, replacing line-multiplication grading with speed-modulation can yield up to ∼80 % shorter slicer-estimated build time. Mechanical behavior was assessed through three-point bending tests on specimens with constant densities (10 %, 20 %, 30 %) and on functionally graded samples with an average density of 10 %. Results show that graded structures, despite their low material content, achieved significantly improved performance over uniform low-density samples, approaching the strength and stiffness of denser configurations. These findings highlight the potential of velocity-based deposition control as an effective tool for rapid manufacturing of lightweight, architected materials with tailored mechanical properties. The approach provides a transferable insight into process optimization for additive manufacturing, supporting the development of faster and more efficient design-to-production workflows.

这项工作介绍了一种新的，工艺驱动的策略，用于制造功能梯度的三周期最小表面（TPMS）结构，通过熔融丝制造，基于通过打印头速度调制控制局部密度。与依赖几何变化或刀具路径复杂性的传统方法不同，该方法在调整打印头速度以改变材料沉积速率的同时保持恒定的切片几何形状：较慢的速度产生更高的密度，而较快的速度导致材料堆积减少。与均匀样品相比，分级样品的构建时间减少了~ 28% %。此外，对于相同的目标密度图，用速度调制代替线乘法分级可以使切片机估计的构建时间缩短约80% %。力学行为是通过三点弯曲试验评估试样恒定密度（10 %,20 %,30 %）和功能分级样品平均密度为10 %。结果表明，尽管梯度结构的材料含量较低，但与均匀的低密度样品相比，梯度结构的性能得到了显著提高，强度和刚度接近于密度较高的结构。这些发现强调了基于速度的沉积控制作为快速制造具有定制机械性能的轻质建筑材料的有效工具的潜力。该方法为增材制造的工艺优化提供了可转移的见解，支持开发更快、更有效的从设计到生产的工作流程。

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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 : 2026-02-01 Epub 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

An approach for integrating performance evaluation and environmental sustainability assessment for hybrid additive-subtractive manufacturing 一种混合增减制造性能评价与环境可持续性评价相结合的方法

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2026-02-01 Epub Date: 2025-12-03 DOI: 10.1016/j.cirpj.2025.11.009

Paolo C. Priarone , Maria Chiara Magnanini

Manufacturing systems that integrate additive and subtractive unit processes within a unified workflow aim to leverage the respective strengths of each technology. This study presents a modeling framework for assessing the environmental performance of hybrid manufacturing systems, explicitly accounting for stochastic system-level dynamics such as blocking (when an upstream process is forced to stop because the downstream buffer is full) and starvation (when a downstream process remains idle because the upstream buffer is empty). The model is applied to a case study combining wire arc additive manufacturing and 5-axis CNC milling, under three different process scenarios and multiple system configurations. Increasing buffer capacity reduces idle states and enables the system to operate closer to its maximum throughput, at the cost of higher work in progress. As productivity increases, specific energy consumption and emissions per part decrease. These findings extend traditional process-level models to a multi-stage context, highlighting the importance of system integration. Overall, the study demonstrates that applying the proposed model can improve energy efficiency and carbon footprint by jointly considering process strategies and system configuration, supporting more informed, sustainability-oriented design and planning decisions.

在统一的工作流程中集成增材和减材单元流程的制造系统旨在利用每种技术的各自优势。本研究提出了一个建模框架，用于评估混合制造系统的环境性能，明确地考虑随机系统级动态，如阻塞（当上游过程因下游缓冲区已满而被迫停止）和饥饿（当下游过程因上游缓冲区空而保持空闲时）。在三种不同的工艺场景和多种系统配置下，将该模型应用于电弧增材制造和五轴数控铣削相结合的案例研究。增加缓冲区容量可以减少空闲状态，使系统更接近其最大吞吐量，但代价是正在进行的工作更多。随着生产率的提高，单位能耗和排放量减少。这些发现将传统的过程级模型扩展到多阶段环境，突出了系统集成的重要性。总体而言，研究表明，通过联合考虑工艺策略和系统配置，应用所提出的模型可以提高能源效率和碳足迹，支持更明智的、以可持续发展为导向的设计和规划决策。

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引用次数: 0