CIRP Journal of Manufacturing Science and Technology最新文献_第5页

Experimental evaluation of 5G performance based on a digital twin of a machine tool 基于机床数字孪生系统的 5G 性能实验评估

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-10-07 DOI: 10.1016/j.cirpj.2024.09.012

Jan Mertes , Christian Schellenberger , Li Yi , Marius Schmitz , Moritz Glatt , Matthias Klar , Bahram Ravani , Hans D. Schotten , Jan C. Aurich

The 5G mobile communication standard can potentially meet the networking requirements for different industrial use cases simultaneously due to the promised low latency, high bandwidth, and high device density while providing a high quality of service. These capabilities enable the realization of digital twins (DTs) that are based on edge computing for time- and safety-critical wireless applications. However, the investigation of the applicability of 5G for DTs in real-world manufacturing scenarios is still lacking. In this work, we have evaluated a DT based on edge-computing and 5G mobile communication using extensive experiments. We have focused on the communication technology and requirements needed to enable functionalities on edge devices. The key contribution of this paper is a comprehensive experimental study on 5G performance characteristics in an existing manufacturing system. Moreover, the influence of 5G on the functionality of the edge-based DT is evaluated and discussed. Full factorial experiments with different network configurations are designed and conducted. The performance of communication characteristics (latency, jitter) is evaluated as well as the impact on the continuity between real and digital processes. The results are also compared with the WiFi standard by experimental evaluation. At last, the limits of current 5G networks for manufacturing are discussed.

5G 移动通信标准具有低延迟、高带宽和高设备密度的特点，可同时满足不同工业用例的网络要求，并提供高质量的服务。这些功能使基于边缘计算的数字孪生（DT）得以实现，用于时间和安全关键型无线应用。然而，5G 在实际制造场景中对数字孪生的适用性还缺乏研究。在这项工作中，我们通过大量实验对基于边缘计算和 5G 移动通信的 DT 进行了评估。我们重点研究了实现边缘设备功能所需的通信技术和要求。本文的主要贡献在于对现有制造系统中的 5G 性能特征进行了全面的实验研究。此外，我们还评估并讨论了 5G 对基于边缘的 DT 功能的影响。本文设计并进行了不同网络配置的全因子实验。评估了通信特性（延迟、抖动）的性能以及对实际流程和数字流程之间连续性的影响。通过实验评估，还将结果与 WiFi 标准进行了比较。最后，讨论了当前 5G 网络在制造业中的局限性。

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引用次数: 0

Physics-supported Bayesian machine learning for chatter prediction with process damping in milling 利用物理贝叶斯机器学习预测铣削过程中的颤振和加工阻尼

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-10-04 DOI: 10.1016/j.cirpj.2024.09.014

Vahid Ostad Ali Akbari , Andrea Eichenberger , Konrad Wegener

Chatter stability of milling operations is a complicated phenomenon causing serious productivity issues in the manufacturing industry, yet a shop-floor implementable solution is lacking. This paper follows a physics-supported Bayesian machine learning approach and incorporates the potential effect of process damping on the stability of the process. Using a likelihood function based on the Nyquist stability criterion, the learning system monitors the actual stability state of the process during arbitrary cuts and refines the underlying model parameter uncertainties in the structural dynamics, cutting force coefficients, as well as the process damping. The framework can operate with limited training data and display the remaining uncertainties in stability predictions to the machine operator. Experimental case studies show the effectiveness of the proposed method and highlight the importance of considering process damping for certain endmills.

铣削操作中的颤振稳定性是一个复杂的现象，在制造业中造成了严重的生产率问题，但却缺乏一种可在车间实施的解决方案。本文采用物理支持的贝叶斯机器学习方法，并将加工阻尼对加工稳定性的潜在影响纳入其中。利用基于奈奎斯特稳定性准则的似然函数，学习系统监控任意切割过程中工艺的实际稳定性状态，并完善结构动力学、切割力系数以及工艺阻尼中的基础模型参数不确定性。该框架可在训练数据有限的情况下运行，并向机器操作员显示稳定性预测中的剩余不确定性。实验案例研究表明了所提方法的有效性，并强调了考虑某些立铣刀加工阻尼的重要性。

引用次数: 0

Numerical modelling and experimental investigations to predict the tool wear of copper electrodes during µ-EDM process 预测 µ-EDM 过程中铜电极工具磨损的数值建模和实验研究

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-10-04 DOI: 10.1016/j.cirpj.2024.09.011

S. Arun, M. Manikandan, Jino Joshy, Basil Kuriachen, Jose Mathew

The micro electrical discharge machining (µ-EDM) process is one of the most widely used techniques to produce miniaturized components in micro-electro mechanical system (MEMS) applications due to its inherent advantages. This work investigates the wear phenomena and the morphology of the copper electrodes during the micro-die sinking process. A numerical model of a single spark is developed assuming the Gaussian distribution of heat flux to estimate the crater dimensions formed in the copper tool electrode (tool wear) used as a result of electric discharge. The crater dimension attained from the ABAQUS finite element model is validated with experimental results using a single spark test setup. Moreover, the effect of input parameters namely capacitance and voltage on the electrode wear rate and surface roughness is also studied. The crater dimensions from the single discharge study are used to formulate the wear model for different possibilities of crater distribution, such as non-overlapping craters, craters with less than 30 % overlap, and 50 % overlap. The electrode wear rate (EWR) also displayed a decline from 20.4 % to 11.6 % and further to 8 % when the overlap was permitted up to 30 % and up to 50 % for the wear model respectively. The developed model results are further compared with experimental results in terms of the electrode wear rate and depth of erosion and the deviations are found to be 20.33 % and 20.55 % respectively

微型放电加工（µ-EDM）工艺因其固有的优势，成为微型机电系统（MEMS）应用中生产微型元件最广泛使用的技术之一。这项工作研究了微模沉积过程中铜电极的磨损现象和形态。假设热通量呈高斯分布，建立了一个单火花数值模型，以估算放电在铜工具电极上形成的凹坑尺寸（工具磨损）。ABAQUS 有限元模型得出的凹坑尺寸与使用单火花测试装置的实验结果进行了验证。此外，还研究了输入参数（电容和电压）对电极磨损率和表面粗糙度的影响。单次放电研究得出的陨石坑尺寸被用于制定不同陨石坑分布可能性的磨损模型，如无重叠陨石坑、重叠率小于 30% 的陨石坑和重叠率为 50% 的陨石坑。当磨损模型允许的重叠率分别达到 30% 和 50%时，电极磨损率 (EWR) 也分别从 20.4% 下降到 11.6%和 8%。就电极磨损率和侵蚀深度而言，所开发模型的结果与实验结果进行了进一步比较，发现偏差分别为 20.33 % 和 20.55 %。

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引用次数: 0

A real-time dual NURBS interpolator with optimised control of flexible acceleration and deceleration for five-axis CNC machining 用于五轴数控加工的实时双 NURBS 插补器，可对灵活的加速和减速进行优化控制

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-10-03 DOI: 10.1016/j.cirpj.2024.09.015

Fei Lou , Hengbo Li , Zhebin Shen , Haorong Zhang , Peng Zhang , Yijie Wu

The limited computing capacity makes it difficult to plan a suitable feedrate profile in real-time for high speed and high accuracy machining of five-axis parametric toolpaths. In this paper, a real-time interpolation algorithm with optimised control of flexible acceleration and deceleration (acc-dec) for the dual NURBS toolpath is proposed. The toolpath is marked as subsegments with similar geometric properties by introducing the five-axis curvature. Machine kinematic and toolpath geometry constraints are considered in the kinematic parameter constraint model. Initial feedrate profiles are solved in a dynamic 3D window which preserves the motion performance of machine tools to a great extent. Convolution is used to smooth the initial feedrate profile to achieve a higher order continuity over the global range. Feedrate fluctuations caused by imprecise parameter interpolation are eliminated through modifying each interpolation periods. Resampling adjusts the position of interpolation points and unify the interpolation periods. All operations mentioned are in series and real-time is strictly guaranteed. Effectiveness of the developed algorithm is validated in simulations and also experimentally on a Self-developed-NC controlled 5-axis machine tool.

由于计算能力有限，很难为五轴参数化刀具路径的高速、高精度加工实时规划合适的进给速度曲线。本文提出了一种实时插补算法，对双 NURBS 刀具路径的柔性加减速（acc-dec）进行了优化控制。通过引入五轴曲率，将刀具路径标记为具有相似几何特性的子段。在运动参数约束模型中考虑了机床运动学和刀具路径几何约束。初始进给速率曲线在动态三维窗口中求解，这在很大程度上保留了机床的运动性能。卷积法用于平滑初始进给速率曲线，以实现全局范围内的高阶连续性。通过修改每个插值周期，消除因参数插值不精确而导致的进给率波动。重新采样可调整插值点的位置，并统一插值周期。上述所有操作都是串联进行的，严格保证了实时性。所开发算法的有效性已在仿真中得到验证，并在自主开发的数控 5 轴机床上进行了实验。

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引用次数: 0

Tool wear prediction based on SVR optimized by hybrid differential evolution and grey wolf optimization algorithms 基于 SVR 的刀具磨损预测，采用混合差分进化和灰狼优化算法进行优化

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-09-27 DOI: 10.1016/j.cirpj.2024.09.013

Jianing Wang , Huiyong Liu , Xiaoling Qi , Yingda Wang , Wei Ma , Song Zhang

Tool wear prediction is key to ensuring product quality and machining efficiency. However, the prediction results of most models are unstable or inaccurate. To address the issues, a tool wear prediction model, based on support vector regression which was optimized by differential evolution and gray wolf optimization algorithms, was proposed in this paper. The method optimized the parameters of support vector regression model through differential evolution and grey wolf optimization algorithms to make the model more balanced in terms of its global and local search capabilities. First, the vibration and power signals were collected by sensors during the milling processes. Then, the features extraction and features selection were performed on the vibration and power signals. Next, the proposed model was developed and trained. Finally, the tool wear was predicted using the proposed model. The results showed that the proposed model had better performance than other models in terms of prediction accuracy and prediction efficiency, and it was applicable to the condition of multiple cutting parameters with generalizability, which will provide some valuable technical support for machining.

刀具磨损预测是确保产品质量和加工效率的关键。然而，大多数模型的预测结果不稳定或不准确。针对这些问题，本文提出了一种基于支持向量回归的刀具磨损预测模型，该模型通过差分进化和灰狼优化算法进行了优化。该方法通过差分进化和灰狼优化算法对支持向量回归模型的参数进行优化，使模型的全局和局部搜索能力更加均衡。首先，通过传感器采集铣削过程中的振动和功率信号。然后，对振动和功率信号进行特征提取和特征选择。然后，开发并训练所提出的模型。最后，使用提出的模型预测刀具磨损。结果表明，所提出的模型在预测精度和预测效率方面都优于其他模型，并且适用于多种切削参数条件，具有普适性，这将为机械加工提供一些有价值的技术支持。

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引用次数: 0

Investigation of the effects of CO2 pre-cooling on the cooling capacity for cryogenic cooling in machining operations 二氧化碳预冷对机械加工中低温冷却能力影响的研究

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-09-24 DOI: 10.1016/j.cirpj.2024.09.007

Trixi Meier, Jan Harald Selzam, Andreas Röckelein, Nico Hanenkamp

Liquid carbon dioxide (LCO₂) based cryogenic cooling has shown promising results in terms of wear reduction, productivity increase and energy efficiency when machining high-temperature materials. For process-safe use with low pulsation, CO₂ must be fed in the liquid state to cool the process zone. LCO₂ is typically stored in riser bottles in which gaseous and liquid aggregate state coexist. A preliminary study has already shown that the liquefied state of the CO₂ can be stabilized by pre-cooling. In this paper, the influence of a heat exchanger as a pre-cooling system on the cooling capacity of the CO₂ is investigated and the required energy consumption is compared to unstabilized CO₂, pressure increased CO₂ and compressed air. It has been shown that pre-cooling leads to a more energy-efficient increase in the cooling capacity of the CO₂ compared to pressure increased CO₂.

在加工高温材料时，基于液态二氧化碳（LCO2）的低温冷却在减少磨损、提高生产率和能源效率方面显示出良好的效果。为保证加工安全和低脉动，二氧化碳必须以液态输入，以冷却加工区。液态二氧化碳通常储存在气态和液态共存的立管瓶中。初步研究表明，通过预冷可以稳定二氧化碳的液化状态。本文研究了作为预冷系统的热交换器对二氧化碳冷却能力的影响，并将所需能耗与未稳定的二氧化碳、压力增加的二氧化碳和压缩空气进行了比较。结果表明，与增压二氧化碳相比，预冷系统能更有效地提高二氧化碳的冷却能力。

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引用次数: 0

A novel approach to enhance formability in Ti-6Al-4V alloy: Experimental investigations and microstructural analysis of pulsating tensile test 提高 Ti-6Al-4V 合金成形性的新方法：脉冲拉伸试验的实验研究和微观结构分析

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-09-24 DOI: 10.1016/j.cirpj.2024.09.008

Habip Gökay Korkmaz , Yusuf Furkan Yapan , Serkan Toros , Mevlüt Türköz

Ti-6Al-4V alloy, widely utilized in aerospace, medical industries, and specialized applications, boasts exceptional properties. However, its limited formability poses challenges in manufacturing processes. The pulsating loading method emerges as a promising solution to enhance formability in such materials. This study delves into the impact of stress relaxation and loading-unloading tests on the formability of Ti‑6Al‑4V alloy, conducting tensile tests on sheets of two different thicknesses: 0.5 mm and 2.65 mm. Investigating parameters such as pulse starting strain, relaxation time, and strain increment in stress relaxation experiments, as well as unloading ratio and strain increment in loading-unloading experiments, enabled a comprehensive comparison of the two pulsating loading methods across different sheet thicknesses. Results indicate a notable increase in material formability, up to approximately 20 % for the 2.65 mm thickness and up to 50 % for the 0.5 mm thickness compared to monotonic loading. Stress relaxation time emerged as the most influential parameter for both thicknesses. Additionally, XRD analysis was employed to elucidate the microstructural reasons behind the observed formability enhancement, while SEM imaging provided insights into the fracture surface morphology. This systematic approach sheds light on the microstructural mechanisms underlying the effect of pulsating loading on material behavior.

Ti-6Al-4V 合金广泛应用于航空航天、医疗行业和特殊用途，具有优异的性能。然而，其有限的可成形性给制造工艺带来了挑战。脉动加载法是提高此类材料成型性的一种可行解决方案。本研究深入探讨了应力松弛和加载-卸载试验对 Ti-6Al-4V 合金成型性的影响，对两种不同厚度的板材进行了拉伸试验：0.5 毫米和 2.65 毫米。通过研究应力松弛实验中的脉冲起始应变、松弛时间和应变增量，以及加载-卸载实验中的卸载率和应变增量等参数，对不同厚度板材的两种脉冲加载方法进行了全面比较。结果表明，与单调加载相比，2.65 毫米厚度的材料成型性显著提高了约 20%，0.5 毫米厚度的材料成型性提高了 50%。应力松弛时间是对两种厚度影响最大的参数。此外，XRD 分析被用来阐明所观察到的成型性提高背后的微观结构原因，而 SEM 成像则提供了对断口表面形态的深入了解。这种系统方法揭示了脉动加载对材料行为产生影响的微观结构机制。

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引用次数: 0

Asymmetric study on the microstructure and mechanical properties of friction stir welded joints: Finite element simulation and experiment 搅拌摩擦焊接接头微观结构和机械性能的非对称研究：有限元模拟和实验

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-09-24 DOI: 10.1016/j.cirpj.2024.09.006

Wei Xue , Liyang Xiao , Changqing Huang , Diqiu He , Xiaoqiang Ren

The local asymmetry in the microstructure of friction stir welded joints in metallic materials is a widespread issue that significantly impacts their mechanical properties. However, the mechanisms underlying this local asymmetry remain unelucidated. This study aimed to investigate the microstructure and mechanical properties of friction stir welded joints in 18 mm-thick aluminum alloy plates. The mechanism underlying the asymmetric local microstructure and mechanical properties was investigated using transmission electron microscopy and finite element simulations. The simulation results revealed that the asymmetric distribution of temperature and equivalent plastic strain between the advancing side and retreating side of the weld led to varied distributions of precipitate phases and dislocation density. Specifically, the peak temperature difference in the transverse direction between the advancing side and retreating side ranged from 11.9 to 35.6 °C, with the advancing side being cooler, while the equivalent plastic strain was slightly higher on the advancing side. Microstructural characterization revealed a decreasing trend in the average volume fraction and size of precipitates on the advancing side in the normal direction. In the transverse direction, the volume fraction of precipitates on the advancing side was two to three times higher than that on the retreating side. Additionally, the geometrically necessary dislocation density was greater on the advancing side, ranging between 0.05 × 10 ¹ ⁴ and 0.20 × 10 ¹ ⁴ m⁻² Theoretical calculations of the strengthening mechanisms indicated that the mechanical property asymmetry between the advancing side and retreating side of the friction stir welded joints was primarily due to dislocation and precipitate strengthening. Mechanical property tests confirmed that the tensile strength and microhardness on the advancing side were significantly higher (by 7–19 MPa and 2–5 HV, respectively) compared to the retreating side, aligning with the theoretical calculations. This study affords valuable insights into friction stir welding technology for metallic materials and provides crucial information and theoretical foundations for optimizing welding processes.

金属材料搅拌摩擦焊接接头微观结构的局部不对称性是一个普遍存在的问题，会严重影响其机械性能。然而，这种局部不对称的内在机制仍未得到阐明。本研究旨在探讨 18 毫米厚铝合金板搅拌摩擦焊点的微观结构和力学性能。利用透射电子显微镜和有限元模拟研究了局部微观结构和力学性能不对称的机理。模拟结果表明，焊缝前进侧和后退侧之间温度和等效塑性应变的非对称分布导致析出相和位错密度的不同分布。具体而言，前进侧和后退侧横向的峰值温差在 11.9 至 35.6 ℃ 之间，前进侧温度较低，而前进侧的等效塑性应变略高。微观结构表征显示，在法线方向上，前进侧析出物的平均体积分数和尺寸呈下降趋势。在横向上，前进侧析出物的体积分数是后退侧的两到三倍。此外，前进侧的几何必要位错密度更大，介于 0.05 × 10 ¹ ⁴ 和 0.20 × 10 ¹ ⁴ m-² 之间。对强化机制的理论计算表明，搅拌摩擦焊接接头前进侧和后退侧的机械性能不对称主要是由于位错和析出物强化造成的。机械性能测试证实，前进侧的抗拉强度和显微硬度明显高于后退侧（分别提高了 7-19 MPa 和 2-5 HV），这与理论计算结果一致。这项研究为金属材料的搅拌摩擦焊接技术提供了宝贵的见解，并为优化焊接工艺提供了重要的信息和理论基础。

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引用次数: 0

Analysis of continuous magnetic field-assisted double-sided incremental forming 连续磁场辅助双面增量成形分析

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-09-23 DOI: 10.1016/j.cirpj.2024.09.004

Hunter R. Enos , Eden Navarrete , Gianluca Buffa , Livan Fratini , Hitomi Yamaguchi

This paper describes the analysis of continuous magnetic field-assisted double-sided incremental forming (M-DSIF), a derivation of magnetic field-assisted single-point incremental forming (M-SPIF). In M-DSIF, the driving magnet remains in contact with the workpiece and does not allow for relaxation between individual steps (called contours). M-DSIF enables forming of truncated cones much faster and more accurately than M-SPIF. The number of revolutions per contour of the tool greatly impacts the resulting shape. The proposed two-step M-DSIF is a viable option for distributing material from the center toward the corners of the cone base, which minimizes localized strain in the corners.

本文介绍了连续磁场辅助双面增量成形（M-DSIF）的分析，它是磁场辅助单点增量成形（M-SPIF）的衍生。在 M-DSIF 中，驱动磁铁与工件保持接触，不允许在单个步骤（称为轮廓）之间放松。与 M-SPIF 相比，M-DSIF 能够更快、更精确地成形截顶锥。刀具每个轮廓的旋转圈数对最终形状有很大影响。建议的两步式 M-DSIF 是一种可行的方案，可将材料从锥体底部的中心向四角分布，从而最大限度地减少四角的局部应变。

引用次数: 0

An improved numerical model of high-speed friction stir welding using a new tool-workpiece slip ratio 利用新的工具-工件滑移比改进高速搅拌摩擦焊数值模型

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2024-09-17 DOI: 10.1016/j.cirpj.2024.09.009

Hepeng Jia , Kai Wu , Rongqing Liang , Rongjian Tai , Fengkun Li

The interface slip state of high-speed friction stir welding (HSFSW) is challenging to determine, and accurate boundary conditions cannot be obtained. First, this paper studies the effects of velocity and temperature on the interface slip state, and establishes a new slip coefficient equation. Then, this equation was used to modify the velocity boundary conditions and improve the numerical calculation method of HSFSW. A numerical model of HSFSW was established and validated through experimental data. Finally, the effects of traverse speed and rotational speed on the temperature and void defects of HSFSW were elaborated, and the applicable process parameter range was determined. Specifically, void defects were observed at a rotational speed of 6000 rpm with traverse speeds of 1000 mm/min and 2000 mm/min, while surface peeling occurred at a traverse speed of 3000 mm/min with a rotational speed of 7000 rpm. This study establishes the optimal parameter range for aluminum alloy HSFSW, providing valuable guidance for future industrial applications.

高速搅拌摩擦焊（HSFSW）的界面滑移状态很难确定，也无法获得精确的边界条件。本文首先研究了速度和温度对界面滑移状态的影响，并建立了一个新的滑移系数方程。然后，利用该方程修改了速度边界条件，改进了 HSFSW 的数值计算方法。建立了 HSFSW 的数值模型，并通过实验数据进行了验证。最后，阐述了横移速度和旋转速度对 HSFSW 温度和空隙缺陷的影响，并确定了适用的工艺参数范围。具体而言，在转速为 6000 rpm、横移速度为 1000 mm/min 和 2000 mm/min 时观察到了空隙缺陷，而在横移速度为 3000 mm/min 和转速为 7000 rpm 时则出现了表面剥落。这项研究确定了铝合金 HSFSW 的最佳参数范围，为未来的工业应用提供了宝贵的指导。

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引用次数: 0