Pub Date : 2024-10-23DOI: 10.1016/j.cirpj.2024.10.011
Di Wu , Jiyuan Tian , Maocheng Liao , Man Zhao , Gang Liu
In the laser directed energy deposition (LDED) process, cyclic thermal stress loading induces significant temperature variations on the surface and subsurface of the workpiece during repeated heating, leading to the formation of residual tensile stress during cooling. This adversely affects the mechanical properties of the parts, causing deformation and defects. In this study, a heat transfer model and a three-dimensional stress model were established based on finite element analysis. A variable laser power (VLP) deposition strategy was proposed to dynamically simulate the temperature and stress fields of Ti6Al4V titanium alloy under different deposition strategies. The model was validated by collecting substrate temperature variations using thermocouples and measuring residual stress with an X-ray diffractometer (XRD). Experimental results showed that the temperature error between the simulation and the experiment ranged from 6.25 % to 10.12 %, with an average stress simulation error of 6.92 %. Among the four strategies, the samples using the VLP strategy showed a reduction in the average substrate temperature by 12.68 % to 15.08 % compared to the other three strategies. The maximum principal stress in the layer was reduced by 7.8 % to 32.14 %, and the residual stress distribution was more uniform in all directions. The microstructure of the deposition layer further indicated that the VLP strategy improves residual stress distribution and leading to better deposition quality.
{"title":"Study on the effect of variable laser power on residual stress distribution in laser directed energy deposition of Ti6Al4V","authors":"Di Wu , Jiyuan Tian , Maocheng Liao , Man Zhao , Gang Liu","doi":"10.1016/j.cirpj.2024.10.011","DOIUrl":"10.1016/j.cirpj.2024.10.011","url":null,"abstract":"<div><div>In the laser directed energy deposition (LDED) process, cyclic thermal stress loading induces significant temperature variations on the surface and subsurface of the workpiece during repeated heating, leading to the formation of residual tensile stress during cooling. This adversely affects the mechanical properties of the parts, causing deformation and defects. In this study, a heat transfer model and a three-dimensional stress model were established based on finite element analysis. A variable laser power (VLP) deposition strategy was proposed to dynamically simulate the temperature and stress fields of Ti6Al4V titanium alloy under different deposition strategies. The model was validated by collecting substrate temperature variations using thermocouples and measuring residual stress with an X-ray diffractometer (XRD). Experimental results showed that the temperature error between the simulation and the experiment ranged from 6.25 % to 10.12 %, with an average stress simulation error of 6.92 %. Among the four strategies, the samples using the VLP strategy showed a reduction in the average substrate temperature by 12.68 % to 15.08 % compared to the other three strategies. The maximum principal stress in the layer was reduced by 7.8 % to 32.14 %, and the residual stress distribution was more uniform in all directions. The microstructure of the deposition layer further indicated that the VLP strategy improves residual stress distribution and leading to better deposition quality.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 322-332"},"PeriodicalIF":4.6,"publicationDate":"2024-10-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531482","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}
Pub Date : 2024-10-22DOI: 10.1016/j.cirpj.2024.10.005
E. Ulular , Y. Altintas , A. Liljerehn
This paper presents digital modeling of shell face mills in milling cylinder heads. The cutter's structural dynamics and its mode shapes are predicted using a Finite Element system. The geometries of the cutter body and inserts are imported from their Computer Aided Design (CAD) models. The insert edge is discretized into small segments to model its varying normal rake and inclination angles, which affect the cutting mechanics. The cutter is dynamically assembled with the target machine tool spindle using the receptance coupling method. A general dynamic cutting force model, which considers the varying edge geometry and inserts’ run-outs, is developed and used to predict cutting forces and chatter stability diagrams. The proposed model is experimentally verified to demonstrate the feasibility of the systematic application of physics-based digital design and analysis of tools for the mass machining of specific parts. The cutter body shape is optimized to increase the stiffness of the bending mode shape that caused chatter via topology optimization, which led to five-fold increase in the absolute stable depth of cut.
{"title":"Digital dynamic modeling and topology optimized design of shell face mills","authors":"E. Ulular , Y. Altintas , A. Liljerehn","doi":"10.1016/j.cirpj.2024.10.005","DOIUrl":"10.1016/j.cirpj.2024.10.005","url":null,"abstract":"<div><div>This paper presents digital modeling of shell face mills in milling cylinder heads. The cutter's structural dynamics and its mode shapes are predicted using a Finite Element system. The geometries of the cutter body and inserts are imported from their Computer Aided Design (CAD) models. The insert edge is discretized into small segments to model its varying normal rake and inclination angles, which affect the cutting mechanics. The cutter is dynamically assembled with the target machine tool spindle using the receptance coupling method. A general dynamic cutting force model, which considers the varying edge geometry and inserts’ run-outs, is developed and used to predict cutting forces and chatter stability diagrams. The proposed model is experimentally verified to demonstrate the feasibility of the systematic application of physics-based digital design and analysis of tools for the mass machining of specific parts. The cutter body shape is optimized to increase the stiffness of the bending mode shape that caused chatter via topology optimization, which led to five-fold increase in the absolute stable depth of cut.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 308-321"},"PeriodicalIF":4.6,"publicationDate":"2024-10-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531481","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}
Pub Date : 2024-10-22DOI: 10.1016/j.cirpj.2024.10.002
Florian Stamer , Roman Girke , Shun Yang , Jung-Hoon Chun , Gisela Lanza
In the realm of production systems, determining the optimal segment allocation remains a central concern. While several existing models address this issue, a significant gap remains as many overlook the critical role of innovation and lack a holistic perspective. This paper presents a model that emphasizes innovation capabilities and introduces the concept of a “Technology Multiplier” underscoring the compounding influence of technology and innovation on production segment allocation decisions. Within this work, we focus on preliminary studies to establish the “Technology Multiplier” concept employing an Analytical Hierarchy Process (AHP) with sensitivity analysis. The validity of our approach is demonstrated through four case studies from three industries, illustrating the relevance of our elaborated metrics for the concept of “Technology Multipliers”. In particular, a leading automotive company uses our findings to reach a more appropriate strategic decision aligned with innovation and production growth, compared to its previous decisions. These results not only demonstrate a robust fit with our proposed metrics but also indicate that our framework lays the foundation for further research on the “Technology Multiplier”, enriching the decision-making process for production segment allocation.
{"title":"Effect of technology multiplier: A framework for analysis of innovation perspectives on production segment allocation","authors":"Florian Stamer , Roman Girke , Shun Yang , Jung-Hoon Chun , Gisela Lanza","doi":"10.1016/j.cirpj.2024.10.002","DOIUrl":"10.1016/j.cirpj.2024.10.002","url":null,"abstract":"<div><div>In the realm of production systems, determining the optimal segment allocation remains a central concern. While several existing models address this issue, a significant gap remains as many overlook the critical role of innovation and lack a holistic perspective. This paper presents a model that emphasizes innovation capabilities and introduces the concept of a “Technology Multiplier” underscoring the compounding influence of technology and innovation on production segment allocation decisions. Within this work, we focus on preliminary studies to establish the “Technology Multiplier” concept employing an Analytical Hierarchy Process (AHP) with sensitivity analysis. The validity of our approach is demonstrated through four case studies from three industries, illustrating the relevance of our elaborated metrics for the concept of “Technology Multipliers”. In particular, a leading automotive company uses our findings to reach a more appropriate strategic decision aligned with innovation and production growth, compared to its previous decisions. These results not only demonstrate a robust fit with our proposed metrics but also indicate that our framework lays the foundation for further research on the “Technology Multiplier”, enriching the decision-making process for production segment allocation.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 272-291"},"PeriodicalIF":4.6,"publicationDate":"2024-10-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531515","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}
Pub Date : 2024-10-22DOI: 10.1016/j.cirpj.2024.10.006
Peng Chen, Sanmin Wang
This paper presents an innovative digital tooth surface precision control model(DTS-PCM) for spiral bevel gears, focusing on the contact parameters derived from the surface synthesis method(SSM) and the pinion tooth surface contact control parameters under Gleason expert manufacturing system(GEMS). This model enables the direct derivation of tooth cutting adjustment parameters for Gleason machine tools, facilitating a seamless integration of design theory with practical processing. Firstly, a novel method for accurately determining the curvature parameters of pinion tooth surfaces, based on predefined contact parameters, has been developed using ease-off topology. Then, based on the pinion gear cutting pitch cone model, a coupled tooth line vector transformation model is proposed to calculate the principal curvature parameters of the nodes. Additionally, a set of equations for the pinion tooth surface contact control parameters is derived, and a formula for calculating the pinion gear cutting adjustment parameters is provided. Finally, two sets of pinion tooth surface contact control parameters were obtained using DTS-PCM: the calculated tooth contact analysis(TCA) and ease-of-topology results. The findings demonstrate that the proposed method is largely consistent with the outcomes of the GEMS calculations, thereby validating the accuracy of DTS-PCM. This indicates that the method can be directly integrated with GEMS software, facilitating practical applications that shorten the design and processing cycle.
{"title":"Digital tooth surface precision control model in spiral bevel gear processing through surface synthesis method combined with GEMS","authors":"Peng Chen, Sanmin Wang","doi":"10.1016/j.cirpj.2024.10.006","DOIUrl":"10.1016/j.cirpj.2024.10.006","url":null,"abstract":"<div><div>This paper presents an innovative digital tooth surface precision control model(DTS-PCM) for spiral bevel gears, focusing on the contact parameters derived from the surface synthesis method(SSM) and the pinion tooth surface contact control parameters under Gleason expert manufacturing system(GEMS). This model enables the direct derivation of tooth cutting adjustment parameters for Gleason machine tools, facilitating a seamless integration of design theory with practical processing. Firstly, a novel method for accurately determining the curvature parameters of pinion tooth surfaces, based on predefined contact parameters, has been developed using ease-off topology. Then, based on the pinion gear cutting pitch cone model, a coupled tooth line vector transformation model is proposed to calculate the principal curvature parameters of the nodes. Additionally, a set of equations for the pinion tooth surface contact control parameters is derived, and a formula for calculating the pinion gear cutting adjustment parameters is provided. Finally, two sets of pinion tooth surface contact control parameters were obtained using DTS-PCM: the calculated tooth contact analysis(TCA) and ease-of-topology results. The findings demonstrate that the proposed method is largely consistent with the outcomes of the GEMS calculations, thereby validating the accuracy of DTS-PCM. This indicates that the method can be directly integrated with GEMS software, facilitating practical applications that shorten the design and processing cycle.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 292-307"},"PeriodicalIF":4.6,"publicationDate":"2024-10-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531516","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}
Pub Date : 2024-10-21DOI: 10.1016/j.cirpj.2024.10.004
Saliha Karadayi-Usta
The Additive Manufacturing (AM) industry is of paramount importance as means of personalized design capabilities by rapid prototyping, using exact amount of required materials avoiding waste, and applying Industry 4.0 technologies with digital transformation ability. The characteristics of AM are regarded as the prerequisites for sustainability in the manufacturing industry. However, there are limited papers discussing the stakeholders and sustainability objectives in a single comprehensive analysis. Hence, the purpose of this research is to identify the degree of each stakeholder to achieve the objective of sustainability in AM supply chain by proposing a novel Plithogenic Fuzzy MACTOR approach. Results reveal that the customers are in triggering position to shape entire AM supply chain as the demand generators. Workforce is a significant player in the AM supply chain by creating the design, manufacturing, marketing, and communicating to provide the collaborations in this business segment. Academia positions here a supportive role to enable the whole supply chain members in terms of delivering technological advancements, training people, and providing the workforce. The AM manufacturers and material / software / printer suppliers are the key players leading to the supply chain by producing the main business products. Thus, a practitioner can interpret its position in the AM supply chain and understand the requirements of sustainability points in detail. Besides, this study provides a theoretical contribution to the literature by extending the MACTOR analysis with Plithogenic sets via including a different uncertainty measure.
快速成型制造(AM)工业作为通过快速原型设计实现个性化设计能力、使用精确数量的所需材料避免浪费以及应用具有数字化转型能力的工业 4.0 技术的手段,具有极其重要的意义。AM 的特性被视为制造业可持续发展的先决条件。然而,通过单一的综合分析来讨论利益相关者和可持续发展目标的论文却非常有限。因此,本研究的目的是通过提出一种新颖的 Plithogenic Fuzzy MACTOR 方法,确定各利益相关者对实现 AM 供应链可持续发展目标的影响程度。研究结果表明,客户作为需求产生者,对整个 AM 供应链的形成具有触发作用。劳动力在 AM 供应链中扮演着重要角色,他们创造设计、制造、营销和交流,为这一业务领域提供合作。学术界在提供技术进步、培训人员和提供劳动力方面发挥着支持整个供应链成员的作用。AM 制造商和材料/软件/打印机供应商是供应链的主要参与者,生产主要的商业产品。因此,从业人员可以解释其在 AM 供应链中的位置,并详细了解可持续性要点的要求。此外,本研究还通过加入不同的不确定性度量,将 MACTOR 分析与 Plithogenic 集进行了扩展,从而为相关文献做出了理论贡献。
{"title":"Sustainable additive manufacturing supply chains with a plithogenic stakeholder analysis: Waste reduction through digital transformation","authors":"Saliha Karadayi-Usta","doi":"10.1016/j.cirpj.2024.10.004","DOIUrl":"10.1016/j.cirpj.2024.10.004","url":null,"abstract":"<div><div>The Additive Manufacturing (AM) industry is of paramount importance as means of personalized design capabilities by rapid prototyping, using exact amount of required materials avoiding waste, and applying Industry 4.0 technologies with digital transformation ability. The characteristics of AM are regarded as the prerequisites for sustainability in the manufacturing industry. However, there are limited papers discussing the stakeholders and sustainability objectives in a single comprehensive analysis. Hence, the purpose of this research is to identify the degree of each stakeholder to achieve the objective of sustainability in AM supply chain by proposing a novel Plithogenic Fuzzy MACTOR approach. Results reveal that the customers are in triggering position to shape entire AM supply chain as the demand generators. Workforce is a significant player in the AM supply chain by creating the design, manufacturing, marketing, and communicating to provide the collaborations in this business segment. Academia positions here a supportive role to enable the whole supply chain members in terms of delivering technological advancements, training people, and providing the workforce. The AM manufacturers and material / software / printer suppliers are the key players leading to the supply chain by producing the main business products. Thus, a practitioner can interpret its position in the AM supply chain and understand the requirements of sustainability points in detail. Besides, this study provides a theoretical contribution to the literature by extending the MACTOR analysis with Plithogenic sets via including a different uncertainty measure.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 261-271"},"PeriodicalIF":4.6,"publicationDate":"2024-10-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531514","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}
Pub Date : 2024-10-19DOI: 10.1016/j.cirpj.2024.10.007
Nicolas Béraud, Yann Ledoux, El-Haddi Mechekour, Frédéric Vignat, Franck Pourroy
Managing the quality of parts produced by the Wire Arc Additive Manufacturing (WAAM) process presents a significant challenge, particularly due to the complexity of thermal control. Effective thermal management is crucial for minimizing defects, making fast and accurate thermal simulations essential for testing and optimizing various manufacturing strategies. This article proposes a rapid simulation that decouples the calculation of heat conduction from convection and radiation. The proposed simulation is described and validated against experimental data. The influences of spatial and temporal discretization are examined. In conclusion, this developed approach provides a fast and efficient simulation of a manufacturing strategy for improvement.
{"title":"Fast thermal simulation of WAAM processing: toward manufacturing strategy evaluation","authors":"Nicolas Béraud, Yann Ledoux, El-Haddi Mechekour, Frédéric Vignat, Franck Pourroy","doi":"10.1016/j.cirpj.2024.10.007","DOIUrl":"10.1016/j.cirpj.2024.10.007","url":null,"abstract":"<div><div>Managing the quality of parts produced by the Wire Arc Additive Manufacturing (WAAM) process presents a significant challenge, particularly due to the complexity of thermal control. Effective thermal management is crucial for minimizing defects, making fast and accurate thermal simulations essential for testing and optimizing various manufacturing strategies. This article proposes a rapid simulation that decouples the calculation of heat conduction from convection and radiation. The proposed simulation is described and validated against experimental data. The influences of spatial and temporal discretization are examined. In conclusion, this developed approach provides a fast and efficient simulation of a manufacturing strategy for improvement.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 234-246"},"PeriodicalIF":4.6,"publicationDate":"2024-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531512","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}
Pub Date : 2024-10-19DOI: 10.1016/j.cirpj.2024.10.008
Kai Ma , Zhanqiang Liu , Bing Wang , Delin Liu
Improving machinability has consistently been an essential research topic in the machining community. However, a rapid and effective method to characterize machinability from the fundamental essence of machining is still lacking. This work proposed a new characterization methodology for assessing machinability from the principle of cutting energy consumption. An original Drop Hammer based Orthogonal Cutting (DHOC) test machine driven by gravitational potential energy was developed to conduct the machinability test. Using the Cutting Distance with Equal Energy (CDEE) method, machinability can be assessed by measuring the cutting distance without expensive measuring apparatus. Therefore, the cutting distance indicator can simplify the test procedure. Meanwhile, the CDEE method avoids the necessity for precisely calculating the consumptions of various complex cutting energies. Moreover, in-situ measurements coupled with the Digital Image Correlation (DIC) technique and Electron Back-Scattered Diffraction (EBSD) characterizations were utilized to evaluate the deformation characteristics and surface integrity during the CDEE tests. The proposed CDEE method has been validated from three aspects involving materials, cutting tools, and surface modification technology. Furthermore, a machinability optimization procedure based on the CDEE method has been proposed. The cutting distance indicator was used as an optimization objective for optimizing technology parameters to improve machinability. This CDEE method based on the DHOC test machine proved to have high application potential for the characterization and optimization of machinability.
{"title":"A new characterization methodology for assessing machinability through cutting energy consumption","authors":"Kai Ma , Zhanqiang Liu , Bing Wang , Delin Liu","doi":"10.1016/j.cirpj.2024.10.008","DOIUrl":"10.1016/j.cirpj.2024.10.008","url":null,"abstract":"<div><div>Improving machinability has consistently been an essential research topic in the machining community. However, a rapid and effective method to characterize machinability from the fundamental essence of machining is still lacking. This work proposed a new characterization methodology for assessing machinability from the principle of cutting energy consumption. An original Drop Hammer based Orthogonal Cutting (DHOC) test machine driven by gravitational potential energy was developed to conduct the machinability test. Using the Cutting Distance with Equal Energy (CDEE) method, machinability can be assessed by measuring the cutting distance without expensive measuring apparatus. Therefore, the cutting distance indicator can simplify the test procedure. Meanwhile, the CDEE method avoids the necessity for precisely calculating the consumptions of various complex cutting energies. Moreover, in-situ measurements coupled with the Digital Image Correlation (DIC) technique and Electron Back-Scattered Diffraction (EBSD) characterizations were utilized to evaluate the deformation characteristics and surface integrity during the CDEE tests. The proposed CDEE method has been validated from three aspects involving materials, cutting tools, and surface modification technology. Furthermore, a machinability optimization procedure based on the CDEE method has been proposed. The cutting distance indicator was used as an optimization objective for optimizing technology parameters to improve machinability. This CDEE method based on the DHOC test machine proved to have high application potential for the characterization and optimization of machinability.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 224-233"},"PeriodicalIF":4.6,"publicationDate":"2024-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531511","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}
Pub Date : 2024-10-19DOI: 10.1016/j.cirpj.2024.10.009
Paolo Posa , Vito Errico , Andrea Angelastro, Sabina Luisa Campanelli
Multi-material fabrication of metals through Additive Manufacturing (AM) processes is attracting more and more attention in recent years. This work presents a novel methodology that enables the fabrication of continuous functionally graded materials (cFGMs) at the layer level using Powder Bed Fusion – Laser Beam (PBF-LB) technology. This has been achieved by designing and building a customized powder separation system that can be easily installed on a currently operating PBF-LB system with a blade/roller-based powder spreading technique (extremely limited for layer-level multi-material fabrication). This technique overcomes one of the main drawbacks of AM multi-material fabrication by properly joining materials with very different mechanical properties and low compatibility, thus extending the productive capacity of this technology. Two steels, AISI 316 L and 18 Ni Maraging 300, with different physical, chemical and mechanical properties, were used to study the applicability and verify the proposed methodology. A high-resolution optical system was used to monitor, layer by layer, the different laser-matter interactions given by the different materials and thus the presence of a graded transition zone between them. Results in terms of statical mechanical properties, microstructure, chemical analysis and optical monitoring showed that the proposed solution is reliable and cost-effective, paving the way for future applications.
近年来,通过增材制造(AM)工艺进行金属的多材料制造正吸引着越来越多的关注。本研究提出了一种新方法,可利用粉末床熔融-激光束(PBF-LB)技术在层级上制造连续功能分级材料(cFGMs)。这是通过设计和建造一个定制的粉末分离系统实现的,该系统可轻松安装在当前运行的 PBF-LB 系统上,并采用基于刀片/滚筒的粉末铺展技术(对于层级多材料制造而言极为有限)。该技术克服了 AM 多材料制造的一个主要缺点,即可以将机械性能迥异、兼容性低的材料适当连接起来,从而提高了该技术的生产能力。我们使用了两种具有不同物理、化学和机械性能的钢材(AISI 316 L 和 18 Ni 马氏体 300)来研究拟议方法的适用性并进行验证。使用高分辨率光学系统逐层监测不同材料产生的不同激光-物质相互作用,从而监测它们之间是否存在分级过渡区。在静态机械性能、微观结构、化学分析和光学监测方面的结果表明,所提出的解决方案既可靠又具有成本效益,为今后的应用铺平了道路。
{"title":"Layer-level fabrication of continuous functionally graded materials (cFGMs) via Powder Bed Fusion – Laser Beam technology","authors":"Paolo Posa , Vito Errico , Andrea Angelastro, Sabina Luisa Campanelli","doi":"10.1016/j.cirpj.2024.10.009","DOIUrl":"10.1016/j.cirpj.2024.10.009","url":null,"abstract":"<div><div>Multi-material fabrication of metals through Additive Manufacturing (AM) processes is attracting more and more attention in recent years. This work presents a novel methodology that enables the fabrication of continuous functionally graded materials (cFGMs) at the layer level using Powder Bed Fusion – Laser Beam (PBF-LB) technology. This has been achieved by designing and building a customized powder separation system that can be easily installed on a currently operating PBF-LB system with a blade/roller-based powder spreading technique (extremely limited for layer-level multi-material fabrication). This technique overcomes one of the main drawbacks of AM multi-material fabrication by properly joining materials with very different mechanical properties and low compatibility, thus extending the productive capacity of this technology. Two steels, AISI 316 L and 18 Ni Maraging 300, with different physical, chemical and mechanical properties, were used to study the applicability and verify the proposed methodology. A high-resolution optical system was used to monitor, layer by layer, the different laser-matter interactions given by the different materials and thus the presence of a graded transition zone between them. Results in terms of statical mechanical properties, microstructure, chemical analysis and optical monitoring showed that the proposed solution is reliable and cost-effective, paving the way for future applications.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 247-260"},"PeriodicalIF":4.6,"publicationDate":"2024-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531513","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}
Pub Date : 2024-10-15DOI: 10.1016/j.cirpj.2024.09.010
Joshua Priest , Sabino Ayvar-Soberanis , Javier Dominguez-Caballero , Peace Onawumi , Zekai Murat Kilic , David Curtis
The mechanistic approach is commonly implemented to predict and optimise the cutting forces in milling processes to prevent tool breakages, reduce tool wear, reduce form error, and improve surface quality. To implement this method, the cutting force coefficients (CFCs), that characterise the mechanics of the process, must be calculated. This study compares the accuracy of the predicted cutting forces for variable pitch and helix bull-nose milling tools using a rapid testing (RT) optimisation-based mechanistic CFC identification method that only requires a single angular cut with increasing radial engagement to the traditional mechanistic approach that requires several straight cuts. Along with developing a hybrid technique that combines variation in feed rate and radial engagement. The traditional radial, tangential, and axial (RTA) force model is also compared with the frictional and normal rake face (UV) force model that is independent of the local tool rake and inclination angles which is a necessary for bull nose tools. The RT and the developed hybrid CFC identification method with the UV force model predicted the average , and cutting forces to within 7.1 %, 4.3 %, and 3.8 % error, respectively. These methods were slightly less accurate than the traditional method, however they have significant industrial benefits because they have can be used to identify CFCs with either a single cut, or from any tool-path with chip-load variation, respectively. The RTA force model predicted the average cutting forces similarly to the UV force model, however, the UV force model had lower errors using the rapid RT testing method at the extreme corners of the experimental design space.
{"title":"Assessment of cutting force coefficient identification methods and force models for variable pitch and helix bull-nose tools","authors":"Joshua Priest , Sabino Ayvar-Soberanis , Javier Dominguez-Caballero , Peace Onawumi , Zekai Murat Kilic , David Curtis","doi":"10.1016/j.cirpj.2024.09.010","DOIUrl":"10.1016/j.cirpj.2024.09.010","url":null,"abstract":"<div><div>The mechanistic approach is commonly implemented to predict and optimise the cutting forces in milling processes to prevent tool breakages, reduce tool wear, reduce form error, and improve surface quality. To implement this method, the cutting force coefficients (CFCs), that characterise the mechanics of the process, must be calculated. This study compares the accuracy of the predicted cutting forces for variable pitch and helix bull-nose milling tools using a rapid testing (RT) optimisation-based mechanistic CFC identification method that only requires a single angular cut with increasing radial engagement to the traditional mechanistic approach that requires several straight cuts. Along with developing a hybrid technique that combines variation in feed rate and radial engagement. The traditional radial, tangential, and axial (RTA) force model is also compared with the frictional and normal rake face (UV) force model that is independent of the local tool rake and inclination angles which is a necessary for bull nose tools. The RT and the developed hybrid CFC identification method with the UV force model predicted the average <span><math><msub><mrow><mi>F</mi></mrow><mrow><mi>x</mi></mrow></msub></math></span>, <span><math><msub><mrow><mi>F</mi></mrow><mrow><mi>y</mi></mrow></msub></math></span> and <span><math><msub><mrow><mi>F</mi></mrow><mrow><mi>z</mi></mrow></msub></math></span> cutting forces to within 7.1 %, 4.3 %, and 3.8 % error, respectively. These methods were slightly less accurate than the traditional method, however they have significant industrial benefits because they have can be used to identify CFCs with either a single cut, or from any tool-path with chip-load variation, respectively. The RTA force model predicted the average cutting forces similarly to the UV force model, however, the UV force model had lower errors using the rapid RT testing method at the extreme corners of the experimental design space.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 210-223"},"PeriodicalIF":4.6,"publicationDate":"2024-10-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142442181","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}
Pub Date : 2024-10-11DOI: 10.1016/j.cirpj.2024.10.001
Z. Arkouli, G. Michalos, G. Kokotinis, S. Makris
Humans are considered the most valuable resource in manufacturing systems thanks to their craftsmanship, dexterity, and autonomy significantly affecting productivity, quality, and the overall company competitiveness. This paper introduces the SAGE (Systematic Approach to Generating Ergonomic Manufacturing tasks) methodology, a structured approach based on Axiomatic Design principles to integrate Human Factors evaluation early in the operations design phase and redesign manufacturing tasks to improve operators well-being. The primary objective is to mitigate discomfort and safety risks that often lead to musculoskeletal disorders, absenteeism, and production delays. SAGE provides a comprehensive framework for assessing ergonomic aspects of manufacturing tasks and identifying the need for redesign. It offers a detailed set of Functional Requirements (FRs) for reference, assesses FR satisfaction, evaluates task complexity using the Independence Axiom, and examines the intensity of FR satisfaction through the Information Axiom. The methodology includes specific implementation guidelines, ensuring its applicability across diverse manufacturing contexts. Its effectiveness is demonstrated through a large-scale parts assembly case study inspired by the bus and coach industrial sector, where a production engineer evaluated a windows assembly task and identified ergonomic design interventions. A comparative analysis with other relevant methods is finally presented, highlighting the approach's effectiveness.
{"title":"Worker-centered evaluation and redesign of manufacturing tasks for ergonomics improvement using axiomatic design principles","authors":"Z. Arkouli, G. Michalos, G. Kokotinis, S. Makris","doi":"10.1016/j.cirpj.2024.10.001","DOIUrl":"10.1016/j.cirpj.2024.10.001","url":null,"abstract":"<div><div>Humans are considered the most valuable resource in manufacturing systems thanks to their craftsmanship, dexterity, and autonomy significantly affecting productivity, quality, and the overall company competitiveness. This paper introduces the SAGE (Systematic Approach to Generating Ergonomic Manufacturing tasks) methodology, a structured approach based on Axiomatic Design principles to integrate Human Factors evaluation early in the operations design phase and redesign manufacturing tasks to improve operators well-being. The primary objective is to mitigate discomfort and safety risks that often lead to musculoskeletal disorders, absenteeism, and production delays. SAGE provides a comprehensive framework for assessing ergonomic aspects of manufacturing tasks and identifying the need for redesign. It offers a detailed set of Functional Requirements (FRs) for reference, assesses FR satisfaction, evaluates task complexity using the Independence Axiom, and examines the intensity of FR satisfaction through the Information Axiom. The methodology includes specific implementation guidelines, ensuring its applicability across diverse manufacturing contexts. Its effectiveness is demonstrated through a large-scale parts assembly case study inspired by the bus and coach industrial sector, where a production engineer evaluated a windows assembly task and identified ergonomic design interventions. A comparative analysis with other relevant methods is finally presented, highlighting the approach's effectiveness.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"55 ","pages":"Pages 188-209"},"PeriodicalIF":4.6,"publicationDate":"2024-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142422120","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}