CIRP Journal of Manufacturing Science and Technology最新文献_第4页

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

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 : 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

Melt pool geometry control of Ti-6Al-4V utilizing multi-energy source laser-arc + wire directed energy deposition 利用多能量源激光电弧+导线定向能沉积技术控制Ti-6Al-4V熔池的几何形状

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-03 DOI: 10.1016/j.cirpj.2025.11.008

James Wainwright , David Rico Sierra , Alec Davis , Stewart Williams , Jialuo Ding

This study investigates the applicability of a novel laser-arc multi-energy deposition of Ti-6Al-4V with independent control of bead geometry and thermal input. A plasma transferred arc is used to generate an initial melt pool and melt wire feedstock, before controlled lateral elongation of the melt pool via a fiber laser and galvo scanner. The applicability to Ti-6Al-4V was first investigated using deposition parameters previously identified. Once successful bead geometry control was achieved, process parameters more conducive to wire directed energy deposition were investigated. This included investigation of the energy per unit area required to achieve accurate deposition of Ti-6Al-4V with minimal penetration and investigation into scanning strategy. In each case, optical microscopy was conducted and analysis of the bead geometry, penetration and heat-affected zone considered to determine the effect of each parameter change. The results demonstrated that independent control of bead geometry and thermal input could be achieved, allowing deposition of Ti-6Al-4V at a desired scan width and layer height and providing a framework for future multi-energy source directed energy deposition of Ti-6Al-4V.

本文研究了一种独立控制磁珠几何形状和热输入的新型激光电弧多能沉积Ti-6Al-4V的适用性。等离子体转移电弧用于产生初始熔池和熔体丝原料，然后通过光纤激光器和galvo扫描仪控制熔池的横向伸长。首先使用先前确定的沉积参数研究了对Ti-6Al-4V的适用性。一旦成功地控制了焊头的几何形状，就可以研究更有利于线材定向能沉积的工艺参数。这包括以最小的渗透实现Ti-6Al-4V精确沉积所需的单位面积能量的研究，以及扫描策略的研究。在每种情况下，都进行了光学显微镜分析，并考虑了焊头的几何形状、穿透性和热影响区，以确定每种参数变化的影响。结果表明，可以实现对磁头几何形状和热输入的独立控制，从而使Ti-6Al-4V在所需的扫描宽度和层高下沉积，并为未来Ti-6Al-4V的多能源定向能沉积提供了框架。

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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 : 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

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 : 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

Modeling multi-directional CFRP cutting mechanics with ply-constraining effect 基于弹性约束效应的CFRP多向切割力学建模

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-11-29 DOI: 10.1016/j.cirpj.2025.11.011

Zhenghui Lu, Xiaoliang Jin

During carbon fiber-reinforced polymer (CFRP) machining, the cutting forces of a multi-directional (MD) laminate can be significantly higher or lower than the superposed cutting forces from unidirectional (UD) laminates for different fiber orientation (FO) combinations, with the underlying mechanism remained unclear. This study proposes a new analytical cutting mechanics model for MD CFRP with ply-constraining effect. The constrained ply in-situ strengths in MD CFRP are derived by determining the onset of crack propagation by fracture mechanics. The cutting strain rate as well as stress for a constrained UD ply with changing FOs are modeled. Then, by strain rate-dependent physics-based failure criteria with in-situ strengths, the material failure of each ply during chip formation is determined. With the model, the failure stress and failure mode of each constrained UD ply with varying FOs are simulated, bringing forth the cutting force prediction for the whole MD laminate. The model-simulated cutting forces agree with experimental values for a series of MD CFRP workpieces with different FO combinations. Distinct ply-constraining effects within different FO ranges are identified and analyzed, which explain the different situations of the cutting force variation from UD laminates to MD laminates for the first time. The study contributes to a new understanding for chip formation and cutting force generation of MD laminates with various FO combinations.

在碳纤维增强聚合物（CFRP）加工过程中，对于不同纤维取向（FO）组合，多向（MD）层压板的切削力可能显著高于或低于单向（UD）层压板的叠加切削力，其潜在机制尚不清楚。本文提出了一种具有塑性约束效应的MD CFRP切削力学分析模型。通过断裂力学方法确定裂纹扩展的起始点，得到了MD CFRP的约束层原位强度。模拟了受约束的厚度随FOs变化时的切削应变率和应力。然后，根据应变率相关的物理失效准则和原位强度，确定了切屑形成过程中每一层的材料失效。利用该模型，模拟了各约束层在不同FOs下的失效应力和失效模式，给出了整个MD层合板的切削力预测。模型模拟的切削力与一系列不同FO组合的MD CFRP工件的实验值吻合。识别并分析了不同FO范围内不同的弹性约束效应，首次解释了UD层合板与MD层合板切削力变化的不同情况。该研究有助于对不同FO组合的MD层压板的切屑形成和切削力的产生有新的认识。

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引用次数: 0

Inverse identification of Johnson–Cook flow stress parameters for Ti6Al4V Ti6Al4V合金Johnson-Cook流变应力参数的反演

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-11-28 DOI: 10.1016/j.cirpj.2025.11.012

Hagen Klippel , Matthias Röthlin , Mohamadreza Afrasiabi , Michal Kuffa , Konrad Wegener

Determining material properties for machining simulations is challenging because direct measurement methods cannot reproduce the conditions of machining. Instead, an inverse parameter identification is used in this work to determine the material parameters for the Johnson-Cook model for Ti6Al4V (3.7165, Grade 5). A numerical simulation model using the smoothed particle hydrodynamics code mfree_iwf is used to recalculate an orthogonal cutting experiment. Due to GPU-acceleration the computational time is less than 5 min per simulation. Three different optimization algorithms (Simplex, Bayes, Differential Evolution) are used for the identification of the material parameters by minimizing the process force errors between experiment and simulation. Best results are obtained with the Differential Evolution algorithm. The sensitivity of material model parameters to the computed process force errors are shown and reveal for some of the material parameters adverse effects on these errors. Recomputations of experiments at different process conditions with the identified material parameters show good agreements in terms of process forces and the chip segmentation behaviour can be reproduced in high resolution simulations.

由于直接测量方法无法再现加工条件，因此确定加工模拟的材料特性具有挑战性。相反，在这项工作中使用了逆参数识别来确定Ti6Al4V（3.7165，等级5）的Johnson-Cook模型的材料参数。采用光滑粒子流体力学程序mfree_iwf建立数值模拟模型，对正交切削实验进行了重新计算。由于gpu加速，每次模拟的计算时间不到5分钟。采用三种不同的优化算法（单纯形、贝叶斯和微分进化），通过最小化实验与仿真之间的过程力误差来识别材料参数。采用差分进化算法得到了最好的结果。分析了材料模型参数对计算过程力误差的敏感性，并揭示了一些材料参数对这些误差的不利影响。用确定的材料参数在不同工艺条件下进行的实验重新计算表明，在工艺力方面具有良好的一致性，并且可以在高分辨率模拟中再现芯片分割行为。

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引用次数: 0

3D geometry prediction for wall deposition using transfer learning in wire arc additive manufacturing 电弧增材制造中基于迁移学习的壁沉积三维几何预测

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-11-26 DOI: 10.1016/j.cirpj.2025.11.007

Hayato Kitagawa , Talash Malek , Daisuke Kono , Berend Denkena

This paper introduces a prediction model for the three-dimensional (3D) geometry of multi-layer single-track (wall-deposition) workpieces in Wire Arc Additive Manufacturing (WAAM), enabling accurate predictions with minimal experimental effort. The model extends a prior single-bead prediction model by incorporating four key enhancements: (1) using multiple cross-sections to capture the full wall geometry, (2) integration of additional input parameters to account for thermal history and deposition sequence, (3) development of an improved geometric-characterization function for better representation of wall geometry, and (4) employing a hybrid dataset composed of synthetic and experimental datasets acquired without specialized equipment, such as in-process geometry measurement systems, thereby simplifying the data collection process. A two-step transfer learning strategy was employed to pretrain the model on a synthetic dataset and subsequently train it using an experimental dataset. This approach enables accurate predictions, even when only a limited amount of experimental data is available. Compared with baseline models without transfer learning, the developed model achieved a substantial reduction in prediction errors, averaging improvements between 5–30 %. Specifically, it attained an error of approximately 10 % for height predictions and 15 % for width predictions. These contributions enhance the adaptability and scalability of the WAAM processes, thereby enabling more efficient and precise manufacturing.

本文介绍了电弧增材制造（WAAM）中多层单轨（壁沉积）工件三维（3D）几何形状的预测模型，能够以最小的实验工作量进行准确的预测。该模型通过纳入四个关键增强功能，扩展了先前的单头预测模型：(1)使用多个横截面来捕获完整的壁面几何形状；(2)集成额外的输入参数，以解释热历史和沉积序列；(3)开发改进的几何表征函数，以更好地表示壁面几何形状；(4)采用混合数据集，由合成数据集和实验数据集组成，无需专业设备（如过程中的几何测量系统）获取。从而简化了数据收集过程。采用两步迁移学习策略在合成数据集上对模型进行预训练，随后使用实验数据集对模型进行训练。这种方法可以实现准确的预测，即使只有有限的实验数据可用。与没有迁移学习的基线模型相比，开发的模型大大降低了预测误差，平均改善幅度在5-30 %之间。具体来说，高度预测的误差约为10 %，宽度预测的误差约为15 %。这些贡献增强了WAAM过程的适应性和可扩展性，从而实现更高效和精确的制造。

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引用次数: 0