Pub Date : 2025-12-01Epub Date: 2025-10-28DOI: 10.1016/j.cirpj.2025.10.005
Sinwon Kim , Yunjae Hwang , Hyung Wook Park , Jisoo Kim , Do Young Kim
Micro-manufacturing processes are essential for technological advances in various industries, such as aerospace, automotive, nuclear, biomedicine, and semiconductors. Especially, micro-machining offers advantages in material selection, dimensional accuracy, and complex geometries. However, burr formation in micro-machined titanium alloy components poses significant challenges for medical implant applications, compromising surface quality and biocompatibility. This study presents a hybrid deburring approach combining abrasive process with O2 plasma large pulsed electron beam (LPEB) irradiation for Ti-6Al-4V micro-channels. Three deburring methods were compared: abrasive, LPEB, and hybrid processing. The hybrid approach achieved superior performance with minimal burr height (16.25 μm) and error area (49.97 μm²), representing 78.26 % and 59.34 % reductions compared to abrasive deburring alone. Surface roughness values of 1.25 μm (top) and 1.12 μm (bottom) were obtained, alongside enhanced hydrophilicity through oxygen vacancy formation and chemical modification. These results demonstrate that LPEB-based hybrid deburring effectively addresses critical requirements for medical implant manufacturing, simultaneously improving geometric accuracy, surface quality, and biocompatibility.
{"title":"Hybrid deburring of micro-machined titanium alloy channels with O2 plasma large pulsed electron beam (LPEB) irradiation","authors":"Sinwon Kim , Yunjae Hwang , Hyung Wook Park , Jisoo Kim , Do Young Kim","doi":"10.1016/j.cirpj.2025.10.005","DOIUrl":"10.1016/j.cirpj.2025.10.005","url":null,"abstract":"<div><div>Micro-manufacturing processes are essential for technological advances in various industries, such as aerospace, automotive, nuclear, biomedicine, and semiconductors. Especially, micro-machining offers advantages in material selection, dimensional accuracy, and complex geometries. However, burr formation in micro-machined titanium alloy components poses significant challenges for medical implant applications, compromising surface quality and biocompatibility. This study presents a hybrid deburring approach combining abrasive process with O<sub>2</sub> plasma large pulsed electron beam (LPEB) irradiation for Ti-6Al-4V micro-channels. Three deburring methods were compared: abrasive, LPEB, and hybrid processing. The hybrid approach achieved superior performance with minimal burr height (16.25 μm) and error area (49.97 μm²), representing 78.26 % and 59.34 % reductions compared to abrasive deburring alone. Surface roughness values of 1.25 μm (top) and 1.12 μm (bottom) were obtained, alongside enhanced hydrophilicity through oxygen vacancy formation and chemical modification. These results demonstrate that LPEB-based hybrid deburring effectively addresses critical requirements for medical implant manufacturing, simultaneously improving geometric accuracy, surface quality, and biocompatibility.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 429-441"},"PeriodicalIF":5.4,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145417640","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 : 2025-12-01Epub Date: 2025-09-26DOI: 10.1016/j.cirpj.2025.09.001
Thomas Jacquet, Jean-Baptiste Guyon, Fabien Viprey, Guillaume Fromentin, David Prat
In modern manufacturing, accurately predicting cutting forces is essential for the design and control of machining operations. Common mechanistic models of cutting forces rely on a precise description of the local uncut chip area. However, in milling, the specific trajectories of cutting edges create challenges in modelling this quantity. Existing analytical models are typically limited to 2D contexts or assume circular tooth trajectories, which are mostly valid for cylindrical end mills. These assumptions limit their applicability to high-feed milling, especially due to low lead angles and complex insert cutter geometries producing non-circular paths. This article presents a new three-dimensional analytical model for evaluating the local uncut chip thickness in high-feed milling. It relies on closed-form expressions derived from geometric analysis and Taylor expansions to approximate the uncut chip area and cutter-workpiece engagement, even in regions where conventional models fail. The model applies to linear-path milling and accounts for tool run-out and differential pitch. Compared to a Newton–Raphson numerical method, it achieves a relative error below 5% while being 3 to 9 times faster, enabling efficient integration in force models. Beyond its computational efficiency, the explicit formulation enables analysis of geometric influence, such as sensitivity to feed per tooth or tooth count-capabilities not easily accessible with purely numerical approaches. This work contributes a rigorous and interpretable alternative for improving cutting force prediction in high-feed milling.
{"title":"Contribution to the analytical determination of uncut chip thickness for cutting force modelling in milling with refinements for high-feed milling","authors":"Thomas Jacquet, Jean-Baptiste Guyon, Fabien Viprey, Guillaume Fromentin, David Prat","doi":"10.1016/j.cirpj.2025.09.001","DOIUrl":"10.1016/j.cirpj.2025.09.001","url":null,"abstract":"<div><div>In modern manufacturing, accurately predicting cutting forces is essential for the design and control of machining operations. Common mechanistic models of cutting forces rely on a precise description of the local uncut chip area. However, in milling, the specific trajectories of cutting edges create challenges in modelling this quantity. Existing analytical models are typically limited to 2D contexts or assume circular tooth trajectories, which are mostly valid for cylindrical end mills. These assumptions limit their applicability to high-feed milling, especially due to low lead angles and complex insert cutter geometries producing non-circular paths. This article presents a new three-dimensional analytical model for evaluating the local uncut chip thickness in high-feed milling. It relies on closed-form expressions derived from geometric analysis and Taylor expansions to approximate the uncut chip area and cutter-workpiece engagement, even in regions where conventional models fail. The model applies to linear-path milling and accounts for tool run-out and differential pitch. Compared to a Newton–Raphson numerical method, it achieves a relative error below 5% while being 3 to 9 times faster, enabling efficient integration in force models. Beyond its computational efficiency, the explicit formulation enables analysis of geometric influence, such as sensitivity to feed per tooth or tooth count-capabilities not easily accessible with purely numerical approaches. This work contributes a rigorous and interpretable alternative for improving cutting force prediction in high-feed milling.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 240-264"},"PeriodicalIF":5.4,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145159330","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 : 2025-12-01Epub Date: 2025-09-27DOI: 10.1016/j.cirpj.2025.09.016
Haowei Zhang, Ningsong Qu
This study presents a novel plasma-enhanced jet electrochemical machining (PE-JEM) method designed to improve the electrochemical machining performance while maintaining process stability. In jet electrochemical machining, the electrolyte jet usually exhibits free flow after increasing the inter-electrode gap, which leads to the natural formation of an air film between the electrode end face and the electrolyte. The high-speed imaging reveals the generation process and locations of plasma generation within the air film, with multiple plasma channels appearing simultaneously at different positions. The current and voltage signals demonstrate the periodic enhancement effect of the plasma, with the anode current density increasing approximately 2.7 times during plasma generation. Notably, the plasma generated in this method does not result in material wear at the tool electrode, ensuring process stability. The jet electrochemical machining experiment confirms significant performance improvements, with a 34.7 % increase in material removal rate and a 48 % increase in groove aspect ratio compared to conventional methods. When the electrode end surface was insulated to suppress plasma generation, the material removal rate and groove aspect ratio declined significantly. These findings highlight plasma-enhanced electrochemical machining as a highly efficient and stable technique for precision manufacturing applications.
{"title":"Phenomena and mechanisms in plasma-enhanced jet electrochemical machining","authors":"Haowei Zhang, Ningsong Qu","doi":"10.1016/j.cirpj.2025.09.016","DOIUrl":"10.1016/j.cirpj.2025.09.016","url":null,"abstract":"<div><div>This study presents a novel plasma-enhanced jet electrochemical machining (PE-JEM) method designed to improve the electrochemical machining performance while maintaining process stability. In jet electrochemical machining, the electrolyte jet usually exhibits free flow after increasing the inter-electrode gap, which leads to the natural formation of an air film between the electrode end face and the electrolyte. The high-speed imaging reveals the generation process and locations of plasma generation within the air film, with multiple plasma channels appearing simultaneously at different positions. The current and voltage signals demonstrate the periodic enhancement effect of the plasma, with the anode current density increasing approximately 2.7 times during plasma generation. Notably, the plasma generated in this method does not result in material wear at the tool electrode, ensuring process stability. The jet electrochemical machining experiment confirms significant performance improvements, with a 34.7 % increase in material removal rate and a 48 % increase in groove aspect ratio compared to conventional methods. When the electrode end surface was insulated to suppress plasma generation, the material removal rate and groove aspect ratio declined significantly. These findings highlight plasma-enhanced electrochemical machining as a highly efficient and stable technique for precision manufacturing applications.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 265-280"},"PeriodicalIF":5.4,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145159331","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 : 2025-12-01Epub Date: 2025-09-17DOI: 10.1016/j.cirpj.2025.09.006
Aswin P., Rakesh G. Mote
High aspect ratio, thin-walled miniature structures are critical in applications such as microfluidics and micromechanical cooling. Wire Electrical Discharge Machining (Wire EDM) presents a commercially viable alternative to specialized micromachining setups for fabricating such features. However, as part size decreases, conventional Wire EDM faces challenges in achieving accurate profiles due to intensified thermal effects and reduced part stiffness, leading to increased geometrical errors. To address this, a reduced-order surrogate framework based on Gaussian Process Regression (GPR) is developed to predict key geometrical deviations specifically, reduced wall thickness and wall deformation as functions of process parameters. The framework integrates four GPR models trained on hybrid datasets combining experimental data and physics-based numerical results. A discrepancy model further refines numerical predictions by accounting for deviations from experimental data. The final GPR models achieve mean absolute errors of 3.39 m and 6.08 m for wall thickness and deformation, with values of 0.96 and 0.99. K-fold cross-validation and validation experiments confirm model reliability, with prediction errors around 14.3 m and 12.1 m. The discrepancy model reduces the deviation of numerical predictions from actual values by 55%. Process parameter optimization is performed to fabricate thin walls with targeted deformation levels, achieving reasonable accuracy within 22.3 m. Furthermore, sensitivity analysis is conducted to quantify both individual and interactive influences of major process parameters on geometrical errors.
{"title":"Gaussian process-based surrogate framework for efficient prediction of geometrical inaccuracy in Wire Electrical Discharge Machining of thin-wall miniature components","authors":"Aswin P., Rakesh G. Mote","doi":"10.1016/j.cirpj.2025.09.006","DOIUrl":"10.1016/j.cirpj.2025.09.006","url":null,"abstract":"<div><div>High aspect ratio, thin-walled miniature structures are critical in applications such as microfluidics and micromechanical cooling. Wire Electrical Discharge Machining (Wire EDM) presents a commercially viable alternative to specialized micromachining setups for fabricating such features. However, as part size decreases, conventional Wire EDM faces challenges in achieving accurate profiles due to intensified thermal effects and reduced part stiffness, leading to increased geometrical errors. To address this, a reduced-order surrogate framework based on Gaussian Process Regression (GPR) is developed to predict key geometrical deviations specifically, reduced wall thickness and wall deformation as functions of process parameters. The framework integrates four GPR models trained on hybrid datasets combining experimental data and physics-based numerical results. A discrepancy model further refines numerical predictions by accounting for deviations from experimental data. The final GPR models achieve mean absolute errors of 3.39 <span><math><mi>μ</mi></math></span>m and 6.08 <span><math><mi>μ</mi></math></span>m for wall thickness and deformation, with <span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span> values of 0.96 and 0.99. K-fold cross-validation and validation experiments confirm model reliability, with prediction errors around 14.3 <span><math><mi>μ</mi></math></span>m and 12.1 <span><math><mi>μ</mi></math></span>m. The discrepancy model reduces the deviation of numerical predictions from actual values by 55%. Process parameter optimization is performed to fabricate thin walls with targeted deformation levels, achieving reasonable accuracy within 22.3 <span><math><mi>μ</mi></math></span>m. Furthermore, sensitivity analysis is conducted to quantify both individual and interactive influences of major process parameters on geometrical errors.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 97-115"},"PeriodicalIF":5.4,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145107772","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 : 2025-12-01Epub Date: 2025-10-25DOI: 10.1016/j.cirpj.2025.10.006
Qiwen Zheng , Shuncheng Kang , Hengrui Li , Yugang Miao , Bintao Wu
For multi-grid aluminium component fabricated by wire-arc directed energy deposition, sharp-corner intersections often experience excessive material accumulation and dimensional deviation. To address this challenge, this study proposed a Flat-Top Corner Model (FTCM) in which sharp vertices were replaced with short linear segments to reduce self-overlapping areas while maintaining intrinsic corner angles. Geometric analysis showed that FTCM could decrease self-overlapping by up to 59 % in 30° corners and 17 % in 90° corners, limiting peak height differences between nodes to less than 3 mm. Experimental validation on X, K, and K′ type nodes further demonstrated that FTCM could improve corner morphology by suppressing localized peak formation, stabilize molten pool dynamics, and enhance layer-to-layer bonding. The research outcomes offer an effective strategy for mitigating material buildup and provide guidance for high-precision and large-scale additive manufacturing of multi-grid component.
{"title":"A new strategy to reduce node accumulation in wire-arc directed energy deposition of multi-grid aluminium structures","authors":"Qiwen Zheng , Shuncheng Kang , Hengrui Li , Yugang Miao , Bintao Wu","doi":"10.1016/j.cirpj.2025.10.006","DOIUrl":"10.1016/j.cirpj.2025.10.006","url":null,"abstract":"<div><div>For multi-grid aluminium component fabricated by wire-arc directed energy deposition, sharp-corner intersections often experience excessive material accumulation and dimensional deviation. To address this challenge, this study proposed a Flat-Top Corner Model (FTCM) in which sharp vertices were replaced with short linear segments to reduce self-overlapping areas while maintaining intrinsic corner angles. Geometric analysis showed that FTCM could decrease self-overlapping by up to 59 % in 30° corners and 17 % in 90° corners, limiting peak height differences between nodes to less than 3 mm. Experimental validation on X, K, and K′ type nodes further demonstrated that FTCM could improve corner morphology by suppressing localized peak formation, stabilize molten pool dynamics, and enhance layer-to-layer bonding. The research outcomes offer an effective strategy for mitigating material buildup and provide guidance for high-precision and large-scale additive manufacturing of multi-grid component.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 393-406"},"PeriodicalIF":5.4,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145362927","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}
Accurate multilayer overlay alignment in photolithography is critical for semiconductor manufacturing. It is crucial to use a limited number of measurement markers to ensure the throughput while maintaining the overlay estimation and control accuracy. This work presents a novel optimization framework for dynamically down-selecting overlay measurement markers. The framework employs a stochastic multilayer control algorithm for tractable real-time control and select an optimal subset of markers that maximize overlay error estimation accuracy. The optimal marker number is determined by maximizing an objective that balances production quality and throughput. Industrial evaluation in a 300 mm fab demonstrates substantial cost-benefit improvements over traditional Run-to-Run control, highlighting enhanced process efficiency and yield.
{"title":"Dynamic decision-making on the number and selection of measurement markers for stochastic control of overlay errors in photolithography","authors":"Yangmeng Li , Huidong Zhang , Noah Graff , Roberto Dailey , Dragan Djurdjanovic","doi":"10.1016/j.cirpj.2025.09.008","DOIUrl":"10.1016/j.cirpj.2025.09.008","url":null,"abstract":"<div><div>Accurate multilayer overlay alignment in photolithography is critical for semiconductor manufacturing. It is crucial to use a limited number of measurement markers to ensure the throughput while maintaining the overlay estimation and control accuracy. This work presents a novel optimization framework for dynamically down-selecting overlay measurement markers. The framework employs a stochastic multilayer control algorithm for tractable real-time control and select an optimal subset of markers that maximize overlay error estimation accuracy. The optimal marker number is determined by maximizing an objective that balances production quality and throughput. Industrial evaluation in a 300 mm fab demonstrates substantial cost-benefit improvements over traditional Run-to-Run control, highlighting enhanced process efficiency and yield.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 227-239"},"PeriodicalIF":5.4,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145159467","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 : 2025-12-01Epub Date: 2025-11-15DOI: 10.1016/j.cirpj.2025.11.005
Adriana Neag , Tudor Balan
The work-hardening curve of sheet metals under large plastic strains can be extracted from the Plane Strain Compression Test (PSCT) using an analytical method that relies on several simplifying assumptions and correction factors (friction, boundary conditions, lateral spreading, tool geometry, yield criterion, anisotropy). This study rigorously assesses each of these correction factors using finite element simulations. Synthetic materials with predefined hardening laws are used to enable direct comparison between the reference curves and those extracted from simulated PSCTs. Dedicated simulation setups were developed to isolate the effect of each factor through progressive 2D and 3D configurations. The results show that the analytical method is generally valid when appropriate corrections are applied, with improved accuracy observed when using rounded tools with small radii under low-friction conditions. Recommendations for the selection of correction factors are provided to enhance the reliability of flow curves obtained through this method.
{"title":"Verification of flow curve determination from plane strain compression tests","authors":"Adriana Neag , Tudor Balan","doi":"10.1016/j.cirpj.2025.11.005","DOIUrl":"10.1016/j.cirpj.2025.11.005","url":null,"abstract":"<div><div>The work-hardening curve of sheet metals under large plastic strains can be extracted from the Plane Strain Compression Test (PSCT) using an analytical method that relies on several simplifying assumptions and correction factors (friction, boundary conditions, lateral spreading, tool geometry, yield criterion, anisotropy). This study rigorously assesses each of these correction factors using finite element simulations. Synthetic materials with predefined hardening laws are used to enable direct comparison between the reference curves and those extracted from simulated PSCTs. Dedicated simulation setups were developed to isolate the effect of each factor through progressive 2D and 3D configurations. The results show that the analytical method is generally valid when appropriate corrections are applied, with improved accuracy observed when using rounded tools with small radii under low-friction conditions. Recommendations for the selection of correction factors are provided to enhance the reliability of flow curves obtained through this method.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 554-565"},"PeriodicalIF":5.4,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145579288","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 : 2025-12-01Epub Date: 2025-11-13DOI: 10.1016/j.cirpj.2025.11.004
Michal Straka , Martin Mareš , Otakar Horejš , Matěj Sulitka , Soyeong Je , Hyeok Kim , Chang-Ju Kim
Machine tool (MT) thermal errors induced by external and internal heat sources are important elements in machined workpiece inaccuracies. In the past few decades, indirect software compensation techniques have been used to address thermal errors due to their economic and ecological advantages. As the sensory equipment of MTs increases, thermal error models can be adapted to regions with higher thermo-mechanical system nonlinearity and inhomogeneity through the introduction of deformation feedback from direct measurements into the model structures. However, adaptive functionalities require discrete interruptions of the MT’s work cycle, which threaten the integrity of the machined surface and complicate the model structure and thus also implementation and industrial deployment possibilities. This research investigates the applicability and validity of touch trigger probe (TTP) measurements for thermal error evaluation on MTs, comparing it with established reference methods. The study examines various operational conditions including no-load, idle heating and machining processes, with particular focus on the method's potential integration into adaptive thermal error compensation systems. Another goal of the paper is to emphasise the need for quality input information for modelling efforts and the industrial applicability of scientific results. Eight experiments were performed on two vertical 5axis milling centres (MT1, MT2) under no-load, idle heating, dry and wet machining, and climate chamber conditions. Results showed that TTP measurements were sufficiently consistent with reference methods under no-load and cool-down transition phases. In spindle idle heating, TTP exhibited nonlinear deviations up to 25 % during the transient part of the behaviour. In case of dry machining, TTP showed a linear deviation of ∼19 % compared to the reference method, which is correctable by a scalar factor. Under wet machining, deviations were negligible due to the homogenising effect of the cutting fluid. Climate chamber tests further confirmed strong ambient temperature dependence and increased error with multiple datum ball (DB) cycles. The study was limited to thermal displacements in the Z-axis. Findings demonstrate that while TTP is not universally reliable, it provides a valuable, industry-relevant approach for updating thermal error models if it is applied in suitable scenarios excluding method's limitations.
{"title":"Study on applicability of touch trigger probes in issues of on-machine measurement of machine tool thermal errors","authors":"Michal Straka , Martin Mareš , Otakar Horejš , Matěj Sulitka , Soyeong Je , Hyeok Kim , Chang-Ju Kim","doi":"10.1016/j.cirpj.2025.11.004","DOIUrl":"10.1016/j.cirpj.2025.11.004","url":null,"abstract":"<div><div>Machine tool (MT) thermal errors induced by external and internal heat sources are important elements in machined workpiece inaccuracies. In the past few decades, indirect software compensation techniques have been used to address thermal errors due to their economic and ecological advantages. As the sensory equipment of MTs increases, thermal error models can be adapted to regions with higher thermo-mechanical system nonlinearity and inhomogeneity through the introduction of deformation feedback from direct measurements into the model structures. However, adaptive functionalities require discrete interruptions of the MT’s work cycle, which threaten the integrity of the machined surface and complicate the model structure and thus also implementation and industrial deployment possibilities. This research investigates the applicability and validity of touch trigger probe (TTP) measurements for thermal error evaluation on MTs, comparing it with established reference methods. The study examines various operational conditions including no-load, idle heating and machining processes, with particular focus on the method's potential integration into adaptive thermal error compensation systems. Another goal of the paper is to emphasise the need for quality input information for modelling efforts and the industrial applicability of scientific results. Eight experiments were performed on two vertical 5axis milling centres (MT1, MT2) under no-load, idle heating, dry and wet machining, and climate chamber conditions. Results showed that TTP measurements were sufficiently consistent with reference methods under no-load and cool-down transition phases. In spindle idle heating, TTP exhibited nonlinear deviations up to 25 % during the transient part of the behaviour. In case of dry machining, TTP showed a linear deviation of ∼19 % compared to the reference method, which is correctable by a scalar factor. Under wet machining, deviations were negligible due to the homogenising effect of the cutting fluid. Climate chamber tests further confirmed strong ambient temperature dependence and increased error with multiple datum ball (DB) cycles. The study was limited to thermal displacements in the <em>Z</em>-axis. Findings demonstrate that while TTP is not universally reliable, it provides a valuable, industry-relevant approach for updating thermal error models if it is applied in suitable scenarios excluding method's limitations.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 522-532"},"PeriodicalIF":5.4,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145528021","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 : 2025-12-01Epub Date: 2025-10-23DOI: 10.1016/j.cirpj.2025.10.003
Naiara Poli Veneziani Sebbe , João Paulo Marques Magalhães Costa , Rafael Resende Lucas , Arnaldo Manuel Guedes Pinto , André Filipe Varandas Pedroso , Francisco José Gomes da Silva , Rita de Cássia Mendonça Sales-Contini
This study aims to enhance the Fused Deposition Modelling (FDM) printing process by utilizing a printing method that deviates from traditional planar techniques and incorporates three-dimensional (3D) layers, assessing the features and qualities of the 3-axis non-planar FDM printing process. To achieve this, the primary specifications of the printer used were analysed and fine-tuned. Planar samples were printed with angles varying from 10º to 30º and extrusion widths between 0.3 mm and 0.7 mm. Concentric and parabolic structures were produced using the planar printing method to examine how the parameters affect the quality of the printed samples. Based on the initial findings, the parameters were refined for printing widths between 0.4 mm and 0.6 mm, while variations were made in printing speed, extrusion multiplier, and overlap. Additionally, investigations were conducted on mechanical strength, increased printing angle (50º to 90º), and roughness assessments of both planar and non-planar surfaces. By constructing a test component to evaluate the practicality of non-planar printing, the findings indicated the potential to modify the 3D printer to produce non-planar forms, thereby improving strength by up to 11 % for non-planar XY mechanical samples and up to 24 % for non-planar Z samples, and featuring designs with diverse angles up to higher angles (90°). The roughness results indicated a 61.7 % improvement in surface quality for the non-planar printing technique and a 34 % improvement for the optimized non-planar printing technique compared to the planar technique. Furthermore, this technique proves to be environmentally friendly as it eliminates the need for support.
{"title":"Improving surface quality and mechanical strength through the optimization and enhancement of Fused Deposition Modelling (FDM) for non-planar 3D printing","authors":"Naiara Poli Veneziani Sebbe , João Paulo Marques Magalhães Costa , Rafael Resende Lucas , Arnaldo Manuel Guedes Pinto , André Filipe Varandas Pedroso , Francisco José Gomes da Silva , Rita de Cássia Mendonça Sales-Contini","doi":"10.1016/j.cirpj.2025.10.003","DOIUrl":"10.1016/j.cirpj.2025.10.003","url":null,"abstract":"<div><div>This study aims to enhance the Fused Deposition Modelling (FDM) printing process by utilizing a printing method that deviates from traditional planar techniques and incorporates three-dimensional (3D) layers, assessing the features and qualities of the 3-axis non-planar FDM printing process. To achieve this, the primary specifications of the printer used were analysed and fine-tuned. Planar samples were printed with angles varying from 10º to 30º and extrusion widths between 0.3 mm and 0.7 mm. Concentric and parabolic structures were produced using the planar printing method to examine how the parameters affect the quality of the printed samples. Based on the initial findings, the parameters were refined for printing widths between 0.4 mm and 0.6 mm, while variations were made in printing speed, extrusion multiplier, and overlap. Additionally, investigations were conducted on mechanical strength, increased printing angle (50º to 90º), and roughness assessments of both planar and non-planar surfaces. By constructing a test component to evaluate the practicality of non-planar printing, the findings indicated the potential to modify the 3D printer to produce non-planar forms, thereby improving strength by up to 11 % for non-planar XY mechanical samples and up to 24 % for non-planar Z samples, and featuring designs with diverse angles up to higher angles (90°). The roughness results indicated a 61.7 % improvement in surface quality for the non-planar printing technique and a 34 % improvement for the optimized non-planar printing technique compared to the planar technique. Furthermore, this technique proves to be environmentally friendly as it eliminates the need for support.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 375-392"},"PeriodicalIF":5.4,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145362928","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}
A dry grinding technique in which the workpiece bulk is utilized as an efficient heat sink for the grinding heat is introduced. In this method, the workpiece is continuously cooled using a refrigeration circuit integrated into the workpiece holding device. This makes the technique different from the traditional cooling or lubrication techniques, whose performance depends on the efficiency of the medium supplied to the grinding zone. The performance of refrigeration-based cooling was compared with liquid cooling and grinding without any cooling, in which the workpiece bulk at room temperature is used as a heat sink. The comparison was made in terms of specific grinding forces, specific grinding energy, temperature, wheel wear, and workpiece quality for specific material removal rates varying between and . The effect of workpiece dimensions on refrigeration-based cooling was also investigated using workpieces with varying volume-to-surface area ratios. Refrigeration cooling was more efficient in reducing grinding forces at a higher specific material removal rate than other techniques. This was attributed to the higher effectiveness of refrigeration cooling in promoting resharpening of the wheel, as inferred through the comparison of wear flat formation on the wheel. The study of the subsurface of the ground specimen indicated the ability of refrigeration cooling to prevent thermal softening. However, at low material removal rates, the beneficial effect of refrigeration cooling was not evident compared to liquid cooling.
{"title":"Refrigeration-based cooling for grinding","authors":"Gibin George, Dinesh Setti, Vineed Narayanan, Pramod Kuntikana","doi":"10.1016/j.cirpj.2025.10.002","DOIUrl":"10.1016/j.cirpj.2025.10.002","url":null,"abstract":"<div><div>A dry grinding technique in which the workpiece bulk is utilized as an efficient heat sink for the grinding heat is introduced. In this method, the workpiece is continuously cooled using a refrigeration circuit integrated into the workpiece holding device. This makes the technique different from the traditional cooling or lubrication techniques, whose performance depends on the efficiency of the medium supplied to the grinding zone. The performance of refrigeration-based cooling was compared with liquid cooling and grinding without any cooling, in which the workpiece bulk at room temperature is used as a heat sink. The comparison was made in terms of specific grinding forces, specific grinding energy, temperature, wheel wear, and workpiece quality for specific material removal rates varying between <span><math><mn>150</mn></math></span> and <span><math><mrow><mn>250</mn><mspace></mspace><msup><mrow><mi>mm</mi></mrow><mn>3</mn></msup><mo>/</mo><mi>min</mi><mo>.</mo><mi>mm</mi></mrow></math></span>. The effect of workpiece dimensions on refrigeration-based cooling was also investigated using workpieces with varying volume-to-surface area ratios. Refrigeration cooling was more efficient in reducing grinding forces at a higher specific material removal rate than other techniques. This was attributed to the higher effectiveness of refrigeration cooling in promoting resharpening of the wheel, as inferred through the comparison of wear flat formation on the wheel. The study of the subsurface of the ground specimen indicated the ability of refrigeration cooling to prevent thermal softening. However, at low material removal rates, the beneficial effect of refrigeration cooling was not evident compared to liquid cooling.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 349-361"},"PeriodicalIF":5.4,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145333310","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}
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