CIRP Journal of Manufacturing Science and Technology最新文献_第7页

Influence of non-planar orientations on solidification microstructure during robot-assisted laser-wire directed energy deposition 机器人辅助激光丝定向能沉积过程中非平面取向对凝固组织的影响

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-09-13 DOI: 10.1016/j.cirpj.2025.09.002

Sumitkumar Rathor , Dhruva Kumar Goyal , Ravi Kant , Ekta Singla

This work investigates the effect of temperature gradient on the solidification morphology during the non-planar laser-wire directed energy deposition (LWDED) process, abbreviated as DED-LB/w according to ISO/ASTM 52900:2021 standard. The LWDED abbreviation is used further in this work. The novelty of this study lies in the independent variation of substrate tilt angle (STA) and wire feed angle (WFA), which presents a comprehensive understanding of non-planar depositions. The temperature distribution and solidification parameters were computed using a customized 3D transient heat transfer model. This numerical model was introduced considering the pulsed laser beam, laser spot shape and size change due to different non-planar orientations. Solidification time, microstructural changes, and heat-affected zone (HAZ) morphology were discussed by correlating the stainless steel 316 L temperature distributions. A numerical and experimental analysis was presented for single-layer deposits. The STA and WFA significantly influence the cooling rates during solidification, affecting the microstructure of the beads. Lower STA (0°-15°) and WFA (10°-20°) result in higher cooling rates. The change in the laser beam spot size affects the solidification rate in the tilt direction due to the lower heating concentration. Smaller WFA (10°-20°) enables the wire to be positioned closer to the molten pool. It results in better energy absorption and efficient melting by increasing temperature. It increased the initial temperature difference and cooling rate. The fraction of equiaxed solidification morphology from the centre to the tilt direction increased with a reduced thermal gradient. The main outcome of this work is the validated solidification map for non-planar LWDED for optimizing deposition strategies in supportless additive manufacturing. The present approach will help suggest the deposition orientations to achieve consistent quality and reliability in deposited parts at non-planar orientations. This work is required to decide deposition strategies for supportless additive manufacturing.

根据ISO/ASTM 52900:2021标准，研究了温度梯度对非平面激光丝定向能沉积（LWDED）过程中凝固形态的影响。LWDED缩写在本工作中进一步使用。本研究的新颖之处在于基材倾斜角度（STA）和送丝角度（WFA）的独立变化，从而对非平面沉积有了全面的了解。使用定制的三维瞬态传热模型计算温度分布和凝固参数。该数值模型考虑了脉冲激光束、光斑形状和尺寸因不同的非平面取向而发生的变化。通过对比316不锈钢 L温度分布，讨论了凝固时间、显微组织变化和热影响区（HAZ）形貌。对单层沉积进行了数值和实验分析。STA和WFA显著影响凝固过程中的冷却速率，从而影响珠的微观组织。较低的STA（0°-15°）和WFA（10°-20°）导致较高的冷却速率。由于加热浓度较低，激光束光斑尺寸的变化影响了倾斜方向的凝固速率。较小的WFA（10°-20°）使焊丝更靠近熔池。通过提高温度，可以更好地吸收能量，提高熔炼效率。增大了初始温差和冷却速率。随着热梯度的减小，从中心到倾斜方向的等轴凝固形貌的比例增加。这项工作的主要成果是验证了非平面LWDED的凝固图，用于优化无支撑增材制造中的沉积策略。本方法将有助于建议沉积方向，以实现非平面取向沉积零件的一致质量和可靠性。这项工作需要确定无支撑增材制造的沉积策略。

{"title":"Influence of non-planar orientations on solidification microstructure during robot-assisted laser-wire directed energy deposition","authors":"Sumitkumar Rathor , Dhruva Kumar Goyal , Ravi Kant , Ekta Singla","doi":"10.1016/j.cirpj.2025.09.002","DOIUrl":"10.1016/j.cirpj.2025.09.002","url":null,"abstract":"<div><div>This work investigates the effect of temperature gradient on the solidification morphology during the non-planar laser-wire directed energy deposition (LWDED) process, abbreviated as DED-LB/w according to ISO/ASTM 52900:2021 standard. The LWDED abbreviation is used further in this work. The novelty of this study lies in the independent variation of substrate tilt angle (STA) and wire feed angle (WFA), which presents a comprehensive understanding of non-planar depositions. The temperature distribution and solidification parameters were computed using a customized 3D transient heat transfer model. This numerical model was introduced considering the pulsed laser beam, laser spot shape and size change due to different non-planar orientations. Solidification time, microstructural changes, and heat-affected zone (HAZ) morphology were discussed by correlating the stainless steel 316 L temperature distributions. A numerical and experimental analysis was presented for single-layer deposits. The STA and WFA significantly influence the cooling rates during solidification, affecting the microstructure of the beads. Lower STA (0°-15°) and WFA (10°-20°) result in higher cooling rates. The change in the laser beam spot size affects the solidification rate in the tilt direction due to the lower heating concentration. Smaller WFA (10°-20°) enables the wire to be positioned closer to the molten pool. It results in better energy absorption and efficient melting by increasing temperature. It increased the initial temperature difference and cooling rate. The fraction of equiaxed solidification morphology from the centre to the tilt direction increased with a reduced thermal gradient. The main outcome of this work is the validated solidification map for non-planar LWDED for optimizing deposition strategies in supportless additive manufacturing. The present approach will help suggest the deposition orientations to achieve consistent quality and reliability in deposited parts at non-planar orientations. This work is required to decide deposition strategies for supportless additive manufacturing.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 43-57"},"PeriodicalIF":5.4,"publicationDate":"2025-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145050315","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}

引用次数: 0

Silver streaks dependence on processing conditions in the injection molding of post-consumer recycled polypropylene 消费后再生聚丙烯注射成型中银纹对加工条件的依赖性

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-09-11 DOI: 10.1016/j.cirpj.2025.09.005

Anna Bortoletto, Andrea Orfano, Marco Sorgato, Giovanni Lucchetta

The growing emphasis on sustainability in plastic waste management has driven interest in recycled polymers, including post-consumer recycled polypropylene. A critical challenge in this field is achieving satisfying aesthetic surface quality in molded components, particularly when defects such as silver streaks arise. This study explores the influence of injection molding processing parameters on the physical and chemical mechanisms underlying defect formation, with a focus on the role of volatile organic compounds released from the degradation of residual inks and binders. Results reveal that silver streaks are significantly influenced by melt temperature, shear rates, and injection speed. These findings not only improve our understanding of how silver streaks form but also suggest practical ways to improve the quality of recycled polypropylene products by adjusting process parameters.

日益强调塑料废物管理的可持续性，推动了对再生聚合物的兴趣，包括消费后再生聚丙烯。该领域的一个关键挑战是在成型组件中实现令人满意的美学表面质量，特别是当出现银纹等缺陷时。本研究探讨了注射成型工艺参数对缺陷形成的物理和化学机制的影响，重点研究了残留油墨和粘合剂降解释放的挥发性有机化合物的作用。结果表明，熔体温度、剪切速率和注射速度对银条有显著影响。这些发现不仅提高了我们对银纹形成的理解，而且为通过调整工艺参数来提高再生聚丙烯产品的质量提供了切实可行的方法。

引用次数: 0

An analytical elastic-plastic contact model for process damping prediction in milling 铣削过程阻尼预测的解析弹塑性接触模型

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-09-11 DOI: 10.1016/j.cirpj.2025.09.004

Yan-Ru Jiang, Xiao-Jian Zhang, Ke-Yan Chen, Si-Hao Mao, Han Ding

Process damping is mainly caused by the dynamic extrusion between the flank face of the tool and the wavy machined surface of workpiece. An accurate description of process damping is critical for predicting stability and optimizing chatter-free cutting parameters. Existing process damping models neglect the extrusion deformation state in the indentation force calculation, and thus cannot reveal the dynamic deformation behavior of the extrusion. This paper presents a general analytical process damping model based on the elastic-plastic contact deformation. The proposed model analyzes three stages of contact deformation, i.e. the elastic regime, mixed elastic-plastic regime, and fully plastic regime, and calculates the indentation force separately for each stage, which avoids additional coefficient identification. Then, the equivalent viscous damping is derived from energy balance to linearize the indentation force and predict stability. The new model is validated by scratching tests and milling experiments, which can predict stability accurately and replace the traditional model.

加工阻尼主要是由刀具侧面与工件波浪形加工表面之间的动态挤压引起的。过程阻尼的准确描述对于预测稳定性和优化无颤振切削参数至关重要。现有的工艺阻尼模型在压痕力计算中忽略了挤压变形状态，无法反映挤压的动态变形行为。提出了一种基于弹塑性接触变形的通用解析过程阻尼模型。该模型分析了接触变形的三个阶段，即弹性状态、弹塑性混合状态和全塑性状态，并分别计算每个阶段的压痕力，避免了额外的系数辨识。然后，根据能量平衡导出等效粘性阻尼，对压痕力进行线性化，并对稳定性进行预测。通过刮伤试验和铣削试验验证了新模型的正确性，该模型能够准确预测工件的稳定性，取代传统模型。

{"title":"An analytical elastic-plastic contact model for process damping prediction in milling","authors":"Yan-Ru Jiang, Xiao-Jian Zhang, Ke-Yan Chen, Si-Hao Mao, Han Ding","doi":"10.1016/j.cirpj.2025.09.004","DOIUrl":"10.1016/j.cirpj.2025.09.004","url":null,"abstract":"<div><div>Process damping is mainly caused by the dynamic extrusion between the flank face of the tool and the wavy machined surface of workpiece. An accurate description of process damping is critical for predicting stability and optimizing chatter-free cutting parameters. Existing process damping models neglect the extrusion deformation state in the indentation force calculation, and thus cannot reveal the dynamic deformation behavior of the extrusion. This paper presents a general analytical process damping model based on the elastic-plastic contact deformation. The proposed model analyzes three stages of contact deformation, i.e. the elastic regime, mixed elastic-plastic regime, and fully plastic regime, and calculates the indentation force separately for each stage, which avoids additional coefficient identification. Then, the equivalent viscous damping is derived from energy balance to linearize the indentation force and predict stability. The new model is validated by scratching tests and milling experiments, which can predict stability accurately and replace the traditional model.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 28-42"},"PeriodicalIF":5.4,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145050316","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}

引用次数: 0

Development and validation of theoretical model for nanofluid minimal quantity lubrication selection in aviation difficult-to-machine materials 航空难加工材料纳米流体最小量润滑选择理论模型的建立与验证

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-09-11 DOI: 10.1016/j.cirpj.2025.09.003

Ben Wang , Qi Zhang , Chang Song , Hao Wang , Tianlong Zhu

Difficult-to-machine aeronautical materials like ceramic matrix composites exhibit high strength and complex machinability, leading to high cutting forces, temperatures, and poor surface quality. Nanofluid minimum quantity lubrication (NMQL) offers excellent friction-reduction and heat-transfer performance, but nanofluid parameter selection remains empirical, lacking theoretical support, which limits its broader engineering application. Accordingly, a theoretical model for nanofluid selection was established by comprehensively considering tribological characteristics, thermophysical properties, dispersion stability, particle concentration, and material compatibility, and was solved using a multi-objective particle swarm optimization algorithm. The input parameters of the model include the physical properties and interfacial behavior characteristics of various base oils and nanoparticles, while the output is the optimal NMQL combination scheme. Results showed that, when applied to 2.5D SiC_f/SiC composites, the optimal solution determined and experimentally validated was palm oil-carbon nanotubes (CNTs)-vol. 2 %. In terms of machining performance, compared with dry grinding (DG), the grinding force under NMQL-CNTs-2 % condition decreased by up to 75.2 %, and the surface roughness decreased by 41.81 %. Meanwhile, the number of rough fracture surfaces was minimized, and fiber wear was minimal, indicating the high accuracy of the optimal solution. In addition, validation was performed using experimental data from existing studies on Ti6Al4V titanium alloy, GH4169 alloy, carbon fiber reinforced polymer (CFRP) composites, and quartz fiber reinforced polyimide (QFRP) composites. The predicted results from the model were consistent with the experimental findings, further demonstrating its applicability and generalizability. The study effectively guides nanofluid selection while providing theoretical support for high-efficiency, precision machining of aeronautical difficult-to-machine materials.

难以加工的航空材料，如陶瓷基复合材料，具有高强度和复杂的可加工性，导致高切削力、高温度和低表面质量。纳米流体最小量润滑（NMQL）具有优异的减摩和换热性能，但纳米流体的参数选择仍然是经验的，缺乏理论支持，限制了其在工程上的广泛应用。基于此，综合考虑摩擦学特性、热物性、分散稳定性、颗粒浓度和材料相容性等因素，建立了纳米流体选择的理论模型，并采用多目标粒子群优化算法进行求解。模型的输入参数包括各种基础油和纳米颗粒的物理性质和界面行为特征，输出为最优的NMQL组合方案。结果表明，当应用于2.5D SiCf/SiC复合材料时，确定并实验验证的最佳溶液为棕榈油-碳纳米管(CNTs)-vol。2 %。在加工性能方面，与干式磨削（DG）相比，NMQL-CNTs-2 %条件下的磨削力降低了75.2% %，表面粗糙度降低了41.81 %。同时，粗断口数量最小，纤维磨损最小，表明最优解具有较高的精度。此外，利用Ti6Al4V钛合金、GH4169合金、碳纤维增强聚合物（CFRP）复合材料和石英纤维增强聚酰亚胺（QFRP）复合材料的现有研究实验数据进行验证。模型的预测结果与实验结果一致，进一步证明了模型的适用性和推广性。该研究有效地指导了纳米流体的选择，同时为航空难加工材料的高效、精密加工提供了理论支持。

{"title":"Development and validation of theoretical model for nanofluid minimal quantity lubrication selection in aviation difficult-to-machine materials","authors":"Ben Wang , Qi Zhang , Chang Song , Hao Wang , Tianlong Zhu","doi":"10.1016/j.cirpj.2025.09.003","DOIUrl":"10.1016/j.cirpj.2025.09.003","url":null,"abstract":"<div><div>Difficult-to-machine aeronautical materials like ceramic matrix composites exhibit high strength and complex machinability, leading to high cutting forces, temperatures, and poor surface quality. Nanofluid minimum quantity lubrication (NMQL) offers excellent friction-reduction and heat-transfer performance, but nanofluid parameter selection remains empirical, lacking theoretical support, which limits its broader engineering application. Accordingly, a theoretical model for nanofluid selection was established by comprehensively considering tribological characteristics, thermophysical properties, dispersion stability, particle concentration, and material compatibility, and was solved using a multi-objective particle swarm optimization algorithm. The input parameters of the model include the physical properties and interfacial behavior characteristics of various base oils and nanoparticles, while the output is the optimal NMQL combination scheme. Results showed that, when applied to 2.5D SiC<sub>f</sub>/SiC composites, the optimal solution determined and experimentally validated was palm oil-carbon nanotubes (CNTs)-vol. 2 %. In terms of machining performance, compared with dry grinding (DG), the grinding force under NMQL-CNTs-2 % condition decreased by up to 75.2 %, and the surface roughness decreased by 41.81 %. Meanwhile, the number of rough fracture surfaces was minimized, and fiber wear was minimal, indicating the high accuracy of the optimal solution. In addition, validation was performed using experimental data from existing studies on Ti6Al4V titanium alloy, GH4169 alloy, carbon fiber reinforced polymer (CFRP) composites, and quartz fiber reinforced polyimide (QFRP) composites. The predicted results from the model were consistent with the experimental findings, further demonstrating its applicability and generalizability. The study effectively guides nanofluid selection while providing theoretical support for high-efficiency, precision machining of aeronautical difficult-to-machine materials.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"63 ","pages":"Pages 12-27"},"PeriodicalIF":5.4,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145050312","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}

引用次数: 0

Crack elimination and synergistic improvement of strength and ductility in directed energy deposited IN738 superalloy via substrate heating and heat treatment 通过基体加热和热处理消除IN738定向能高温合金的裂纹并协同提高其强度和塑性

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-09-03 DOI: 10.1016/j.cirpj.2025.08.009

Mingzhang Chen , Lin Hua , Zeqi Hu , Xunchen Liu , Xunpeng Qin

During the directed energy deposition (DED) process of IN738 superalloy, elevated thermal stresses and low-ductility γ′ phase can lead to crack formation. To tackle the cracking issue, this study developed a substrate heating platform within the DED apparatus, raising the substrate temperature to 300 °C to diminish the temperature gradient and thermal stress, while also optimizing laser power and scanning speed to achieve DED crack-free IN738. On-site thermal imaging and numerical simulations indicated that the temperature gradient and thermal stress in the samples gradually diminished with rising substrate temperatures and optimized process parameters. Moreover, microstructural characterization results revealed that heating the substrate to 300 °C reduced the content of the γ′ phase, while optimizing process parameters further refined the grains. The combination of reduced thermal stress, grain refinement, and diminished γ′ phase volume fraction collectively enabled the DED of crack-free IN738. On the crack-free DED IN738, a solution treatment at 1120°C for two hours notably improved its mechanical properties. The solution treatment simultaneously eliminated the Laves phase and generated finer γ′ phases along with a bimodal structure. These strengthening mechanisms effectively enhanced strength and ductility. Digital image correlation (DIC) and fractographic analyses substantiated that the solution treatment improved the coordinated deformation ability and the solubility of certain carbides reduced defects, further enhancing strength and ductility. Interestingly, a subsequent 24-hour aging treatment at 850°C did not significantly improve properties due to γ′ phase coarsening and δ phase precipitation.

在IN738高温合金定向能沉积（DED）过程中，较高的热应力和低塑性γ′相可导致裂纹的形成。为了解决裂纹问题，本研究在DED设备内开发了衬底加热平台，将衬底温度提高到300 °C，以减小温度梯度和热应力，同时优化激光功率和扫描速度，以实现DED无裂纹IN738。现场热成像和数值模拟结果表明，随着衬底温度的升高和工艺参数的优化，样品中的温度梯度和热应力逐渐减小。此外，显微组织表征结果表明，将衬底加热到300 °C降低了γ′相的含量，同时优化工艺参数进一步细化了晶粒。热应力的降低、晶粒的细化和γ′相体积分数的降低共同使IN738的DED无裂纹。对无裂纹DED IN738进行1120℃固溶处理2小时，其力学性能得到显著改善。固溶处理同时消除了Laves相，生成了更细的γ′相和双峰结构。这些强化机制有效地提高了强度和延展性。数字图像相关（DIC）和断口分析证实，固溶处理提高了合金的协调变形能力，某些碳化物的溶解度降低了缺陷，进一步提高了合金的强度和塑性。有趣的是，随后在850℃下进行24小时时效处理，由于γ′相粗化和δ相析出，性能没有显著改善。

{"title":"Crack elimination and synergistic improvement of strength and ductility in directed energy deposited IN738 superalloy via substrate heating and heat treatment","authors":"Mingzhang Chen , Lin Hua , Zeqi Hu , Xunchen Liu , Xunpeng Qin","doi":"10.1016/j.cirpj.2025.08.009","DOIUrl":"10.1016/j.cirpj.2025.08.009","url":null,"abstract":"<div><div>During the directed energy deposition (DED) process of IN738 superalloy, elevated thermal stresses and low-ductility γ′ phase can lead to crack formation. To tackle the cracking issue, this study developed a substrate heating platform within the DED apparatus, raising the substrate temperature to 300 °C to diminish the temperature gradient and thermal stress, while also optimizing laser power and scanning speed to achieve DED crack-free IN738. On-site thermal imaging and numerical simulations indicated that the temperature gradient and thermal stress in the samples gradually diminished with rising substrate temperatures and optimized process parameters. Moreover, microstructural characterization results revealed that heating the substrate to 300 °C reduced the content of the γ′ phase, while optimizing process parameters further refined the grains. The combination of reduced thermal stress, grain refinement, and diminished γ′ phase volume fraction collectively enabled the DED of crack-free IN738. On the crack-free DED IN738, a solution treatment at 1120°C for two hours notably improved its mechanical properties. The solution treatment simultaneously eliminated the Laves phase and generated finer γ′ phases along with a bimodal structure. These strengthening mechanisms effectively enhanced strength and ductility. Digital image correlation (DIC) and fractographic analyses substantiated that the solution treatment improved the coordinated deformation ability and the solubility of certain carbides reduced defects, further enhancing strength and ductility. Interestingly, a subsequent 24-hour aging treatment at 850°C did not significantly improve properties due to γ′ phase coarsening and δ phase precipitation.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"62 ","pages":"Pages 59-74"},"PeriodicalIF":5.4,"publicationDate":"2025-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144932735","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}

引用次数: 0

Analytical prediction of surface morphology and residual stress induced by milling and ultrasonic surface rolling 铣削和超声表面轧制表面形貌及残余应力的分析预测

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-08-30 DOI: 10.1016/j.cirpj.2025.08.005

Junfeng Xiang , Aobo Song , Haojie Ding , Xiangping Zou , Lijing Xie , Jie Yi , Dong Han

Shape-controlled milling and integrity-controlled ultrasonic surface rolling processing (USRP) is an effective sequential machining method that enhances the surface integrity of metallic materials by reducing surface roughness (SR), increasing compressive residual stress (CRS), and improving fatigue resistance. However, accurately predicting the surface morphology and CRS during multi-process sequence remains a challenge. This study establishes analytical predictive models for the surface morphology and CRS of TC21 titanium alloy after milling and subsequent USRP, explicitly considering the initial surface state induced by milling. A surface morphology prediction model for USRP was then developed, incorporating the initial milled surface topography, revealing that USRP effectively eliminates surface peaks but does not fill concave valleys, necessitating the consideration of initial surface conditions for accurate predictions. By integrating milling-induced initial residual stress fields (IRSF), hardness variations, and yield strength modifications, an analytical model for CRS prediction based on Hertzian contact theory and elastoplastic deformation was formulated. The accuracy of the proposed models was verified through finite element simulation and experiment measurements. The findings highlight the necessity of incorporating initial surface integrity when modeling multi-process machining and provide a foundational approach for optimizing surface integrity in titanium alloy components.

形状控制铣削和完整性控制超声表面轧制加工（USRP）是一种有效的顺序加工方法，可以通过降低表面粗糙度（SR）、增加压缩残余应力（CRS）和提高抗疲劳性来提高金属材料的表面完整性。然而，在多工艺序列中准确预测表面形貌和CRS仍然是一个挑战。本研究明确考虑铣削引起的初始表面状态，建立了TC21钛合金铣削后及后续USRP后的表面形貌和CRS的分析预测模型。然后开发了USRP的表面形貌预测模型，结合初始铣削表面形貌，表明USRP有效地消除了表面峰，但没有填充凹谷，因此需要考虑初始表面条件才能进行准确预测。通过综合铣削初始残余应力场、硬度变化和屈服强度变化，建立了基于赫兹接触理论和弹塑性变形的CRS预测分析模型。通过有限元仿真和实验测量验证了所提模型的准确性。研究结果强调了在多工序加工建模时考虑初始表面完整性的必要性，并为优化钛合金零件的表面完整性提供了基础方法。

{"title":"Analytical prediction of surface morphology and residual stress induced by milling and ultrasonic surface rolling","authors":"Junfeng Xiang , Aobo Song , Haojie Ding , Xiangping Zou , Lijing Xie , Jie Yi , Dong Han","doi":"10.1016/j.cirpj.2025.08.005","DOIUrl":"10.1016/j.cirpj.2025.08.005","url":null,"abstract":"<div><div>Shape-controlled milling and integrity-controlled ultrasonic surface rolling processing (USRP) is an effective sequential machining method that enhances the surface integrity of metallic materials by reducing surface roughness (SR), increasing compressive residual stress (CRS), and improving fatigue resistance. However, accurately predicting the surface morphology and CRS during multi-process sequence remains a challenge. This study establishes analytical predictive models for the surface morphology and CRS of TC21 titanium alloy after milling and subsequent USRP, explicitly considering the initial surface state induced by milling. A surface morphology prediction model for USRP was then developed, incorporating the initial milled surface topography, revealing that USRP effectively eliminates surface peaks but does not fill concave valleys, necessitating the consideration of initial surface conditions for accurate predictions. By integrating milling-induced initial residual stress fields (IRSF), hardness variations, and yield strength modifications, an analytical model for CRS prediction based on Hertzian contact theory and elastoplastic deformation was formulated. The accuracy of the proposed models was verified through finite element simulation and experiment measurements. The findings highlight the necessity of incorporating initial surface integrity when modeling multi-process machining and provide a foundational approach for optimizing surface integrity in titanium alloy components.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"62 ","pages":"Pages 38-58"},"PeriodicalIF":5.4,"publicationDate":"2025-08-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144917964","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}

引用次数: 0

The role of material properties in modeling maximal surface temperatures and heat distribution in milling of UD CFRP 材料性能在UD CFRP铣削最高表面温度和热分布建模中的作用

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-08-27 DOI: 10.1016/j.cirpj.2025.08.002

Wolfgang Hintze, Ganna Shchegel, Jan Mehnen, Carsten Möller, Jan Dege

In order to meet the precision requirements for components made of carbon fibre reinforced plastics (CFRP), the edges are often trimmed by milling. However, this can lead to detrimental thermal damage to the machined surface. The aim of the study was to investigate in detail the maximum temperatures and characteristic thermal parameters for various unidirectional CFRP materials under different cutting conditions. During upcut milling using a PCD cutter an infrared camera, thermocouples and a dynamometer were employed to monitor temperatures and the cutting power. An analytical heat flow model suitable for arbitrary fibre orientation angles was used to determine, based on thermal material properties, the temperature change at the machined surface and the heat flow parameters from experiments. Material influence on the cutting power was considered by its specific elastic energy at fracture depending on the volume content and mechanical properties of the fibres. At the machined surface, the resin glass transition temperatures were frequently exceeded, and the highest temperature changes were observed at a fibre orientation angle of Φ = 135°. In most cases, higher cutting speeds were accompanied by greater temperature changes. Phenomenological models of the thermal parameters of the machining process were developed, which take into account both the thermal and mechanical CFRP properties and show a good correlation with the experimental results. They provide benefits in order to predict the temperature fields for materials with differing properties and under varying cutting conditions.

为了满足碳纤维增强塑料（CFRP）部件的精度要求，通常采用铣削方法对其边缘进行修整。然而，这可能会对加工表面造成有害的热损伤。研究的目的是详细研究不同单向CFRP材料在不同切割条件下的最高温度和特征热参数。在使用PCD刀具进行上切铣削时，采用红外摄像机、热电偶和测功仪来监测温度和切削功率。基于热工材料的特性，建立了适用于任意纤维取向角的解析热流模型，确定了加工表面的温度变化和实验热流参数。根据纤维的体积含量和力学性能，通过断裂时的比弹性能来考虑材料对切割功率的影响。在加工表面，树脂玻璃化转变温度经常超过，纤维取向角Φ = 135°时温度变化最大。在大多数情况下，更高的切削速度伴随着更大的温度变化。建立了加工过程热参数的唯象模型，该模型同时考虑了CFRP的热性能和力学性能，并与实验结果具有良好的相关性。它们为预测具有不同性能和不同切削条件下的材料的温度场提供了好处。

{"title":"The role of material properties in modeling maximal surface temperatures and heat distribution in milling of UD CFRP","authors":"Wolfgang Hintze, Ganna Shchegel, Jan Mehnen, Carsten Möller, Jan Dege","doi":"10.1016/j.cirpj.2025.08.002","DOIUrl":"10.1016/j.cirpj.2025.08.002","url":null,"abstract":"<div><div>In order to meet the precision requirements for components made of carbon fibre reinforced plastics (CFRP), the edges are often trimmed by milling. However, this can lead to detrimental thermal damage to the machined surface. The aim of the study was to investigate in detail the maximum temperatures and characteristic thermal parameters for various unidirectional CFRP materials under different cutting conditions. During upcut milling using a PCD cutter an infrared camera, thermocouples and a dynamometer were employed to monitor temperatures and the cutting power. An analytical heat flow model suitable for arbitrary fibre orientation angles was used to determine, based on thermal material properties, the temperature change at the machined surface and the heat flow parameters from experiments. Material influence on the cutting power was considered by its specific elastic energy at fracture depending on the volume content and mechanical properties of the fibres. At the machined surface, the resin glass transition temperatures were frequently exceeded, and the highest temperature changes were observed at a fibre orientation angle of Φ = 135°. In most cases, higher cutting speeds were accompanied by greater temperature changes. Phenomenological models of the thermal parameters of the machining process were developed, which take into account both the thermal and mechanical CFRP properties and show a good correlation with the experimental results. They provide benefits in order to predict the temperature fields for materials with differing properties and under varying cutting conditions.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"62 ","pages":"Pages 24-37"},"PeriodicalIF":5.4,"publicationDate":"2025-08-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144903337","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}

引用次数: 0

Effect of quasi-isothermal hot forging and isothermal roll forming on the microstructure of a wrought nickel-based superalloy 准等温热锻和等温滚压成形对变形镍基高温合金显微组织的影响

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-08-23 DOI: 10.1016/j.cirpj.2025.08.007

Sh.Kh. Mukhtarov, A.A. Ganeev, R.V. Shakhov, V.M. Imayev

In the present work, the novel processing route including isothermal roll forming was applied for obtaining a disc workpiece intended for subsequent manufacturing of a disc, which could be used in gas turbine engines. A wrought nickel-based superalloy Ni-10.3(Al,Ti,Nb)-31.6(Co,Cr,Mo,W) (wt%) (Russian abbreviation ЭП962) was taken as a starting material. In the as-received condition, the superalloy had the microstructure with a γ grain size of about 50 µm. From the as-received superalloy the billet with a size of Ø200 × 315 mm was cut and put into a can made of a stainless steel. The canned billet was subjected to three-stage subsolvus forging under quasi-isothermal conditions with intermediate annealing. As a result, the pancake with a size of about Ø410 × 75 mm was produced. Microstructural examination showed that predominantly recrystallized and fine-grained structure (d<10 µm) was formed in the central part of the pancake, while coarser microstructure was preserved near the flat surfaces of the pancake. Before roll forming, the central part of the pancake with a diameter of 70 mm was cut out and used to make small cylindrical samples, which were compressed at 1100°C with switching of the strain rate to determine the strain rate sensitivity coefficient m and thus the superplastic conditions. The obtained workpiece was then subjected to isothermal subsolvus roll forming under near superplastic conditions at T = 1100 ± 15°C and έ= 5 × 10⁻⁴-5 × 10⁻³ s⁻¹. Complex-shaped disc workpiece with a size of about Ø510 × (35−70) mm was produced. Microstructural analysis of the produced disc workpiece showed that recrystallized and gradient microstructure was formed after roll forming. The average γ grain sizes changed from d≈ 9.7 µm in the bore zone to d≈ 8.8 µm in the web zone and to d≈ 20 µm in the rim zone of the disc workpiece. The advantages of using this processing to manufacture near-net shaped discs for gas turbine engines are discussed.

本文采用等温滚压成形的新型加工路线，获得了用于燃气涡轮发动机的圆盘工件，并用于后续的圆盘制造。以镍基高温合金Ni-10.3(Al,Ti,Nb)-31.6(Co,Cr,Mo，W) (wt%)（俄文缩写ЭП962）为起始材料。在接收条件下，合金的γ晶粒尺寸约为50 µm。从收到的高温合金中切割出尺寸为Ø200 × 315 mm的钢坯，放入不锈钢罐中。在准等温条件下对钢坯进行了三段亚溶剂锻造和中间退火。最终得到了尺寸约为Ø410 × 75 mm的烧饼。显微组织检查表明，烧饼中部形成了以再结晶为主的细晶组织（d<10 µm），而靠近烧饼平面处则保持了较粗的组织。在滚压成形前，将直径为70 mm的煎饼的中心部分切下，制成小圆柱形试样，在1100℃下进行压缩，改变应变速率，确定应变速率敏感系数m，从而确定超塑性条件。获得的工件就被等温subsolvus附近超塑性条件下辊轧成形1100 T =  ± 15°C和έ= 5 × 10−4 - 5 × 10−3 s−1。加工出尺寸约为Ø510 × （35−70）mm的复杂形状圆盘工件。对加工后的盘状工件进行显微组织分析表明，辊压成形后形成了再结晶和梯度组织。平均γ晶粒尺寸从孔区d≈ 9.7 µm到腹板区d≈ 8.8 µm，再到边缘区d≈ 20 µm。讨论了采用该工艺制造燃气涡轮发动机近净形盘的优点。

{"title":"Effect of quasi-isothermal hot forging and isothermal roll forming on the microstructure of a wrought nickel-based superalloy","authors":"Sh.Kh. Mukhtarov, A.A. Ganeev, R.V. Shakhov, V.M. Imayev","doi":"10.1016/j.cirpj.2025.08.007","DOIUrl":"10.1016/j.cirpj.2025.08.007","url":null,"abstract":"<div><div>In the present work, the novel processing route including isothermal roll forming was applied for obtaining a disc workpiece intended for subsequent manufacturing of a disc, which could be used in gas turbine engines. A wrought nickel-based superalloy Ni-10.3(Al,Ti,Nb)-31.6(Co,Cr,Mo,W) (wt%) (Russian abbreviation ЭП962) was taken as a starting material. In the as-received condition, the superalloy had the microstructure with a γ grain size of about 50 µm. From the as-received superalloy the billet with a size of Ø200 × 315 mm was cut and put into a can made of a stainless steel. The canned billet was subjected to three-stage subsolvus forging under quasi-isothermal conditions with intermediate annealing. As a result, the pancake with a size of about Ø410 × 75 mm was produced. Microstructural examination showed that predominantly recrystallized and fine-grained structure (d<10 µm) was formed in the central part of the pancake, while coarser microstructure was preserved near the flat surfaces of the pancake. Before roll forming, the central part of the pancake with a diameter of 70 mm was cut out and used to make small cylindrical samples, which were compressed at 1100°C with switching of the strain rate to determine the strain rate sensitivity coefficient m and thus the superplastic conditions. The obtained workpiece was then subjected to isothermal subsolvus roll forming under near superplastic conditions at T = 1100 ± 15°C and έ= 5 × 10<sup>−4</sup>-5 × 10<sup>−3</sup> s<sup>−1</sup>. Complex-shaped disc workpiece with a size of about Ø510 × (35−70) mm was produced. Microstructural analysis of the produced disc workpiece showed that recrystallized and gradient microstructure was formed after roll forming. The average γ grain sizes changed from d≈ 9.7 µm in the bore zone to d≈ 8.8 µm in the web zone and to d≈ 20 µm in the rim zone of the disc workpiece. The advantages of using this processing to manufacture near-net shaped discs for gas turbine engines are discussed.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"62 ","pages":"Pages 16-23"},"PeriodicalIF":5.4,"publicationDate":"2025-08-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144889308","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}

引用次数: 0

Tool trajectory planning with inter-path consistency of feedrate for freeform surface machining 自由曲面加工中刀具轨迹规划与进给速度的路径一致性

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-08-13 DOI: 10.1016/j.cirpj.2025.08.003

Shu Wang , Hui Zhang , Bingran Li , Peiqing Ye

For CNC machining of freeform surfaces, inter-path inconsistency of feedrate for tool trajectories can lead to surface defects such as overcutting, undercutting, and uneven tool marks, significantly affecting the surface quality of workpieces. However, existing tool trajectory planning methods typically focus only on motion planning for a single toolpath in the feed direction while neglecting the toolpath reference information in the cross-feed direction, which limits the potential improvement in machining quality. To address this issue, a tool trajectory planning method with inter-path consistency of feedrate is proposed in this paper, which includes an inter-path mapping and consistent redistribution algorithm for tool position points, as well as a feedrate planning algorithm based on interpolation between sub-toolpaths. By referring to the position and feedrate information of adjacent sub-toolpaths, the proposed method can achieve a more uniform feedrate distribution in the cross-feed direction. Additionally, to evaluate the effectiveness of the proposed method in optimizing inter-path consistency of feedrate, two evaluation indicators, inter-path feedrate distribution cosine similarity and feedrate gradient in cross-feed direction, are introduced. Simulation and experimental results demonstrate the feasibility and effectiveness of the proposed method, showing that it can significantly improve inter-path consistency of feedrate compared to conventional methods, and finally enhance surface quality and machining efficiency.

在自由曲面的数控加工中，刀具轨迹进给速度的路径间不一致会导致过切、欠切、刀痕不均匀等表面缺陷，严重影响工件的表面质量。然而，现有的刀具轨迹规划方法通常只关注进给方向上单个刀路的运动规划，而忽略了交叉进给方向上的刀路参考信息，限制了加工质量的潜在提高。针对这一问题，本文提出了一种具有进给速度路径一致性的刀具轨迹规划方法，该方法包括刀具位置点的路径间映射和一致性再分配算法，以及基于子刀具路径间插值的进给速度规划算法。通过参考相邻子刀具路径的位置和进给速度信息，该方法可以在交叉进给方向上实现更均匀的进给速度分布。此外，为了评价该方法在优化进给速度一致性方面的有效性，引入了两个评价指标，即进给速度分布余弦相似性和跨进给方向的进给速度梯度。仿真和实验结果验证了该方法的可行性和有效性，表明与传统方法相比，该方法可以显著提高进给速度的路径一致性，从而提高表面质量和加工效率。

{"title":"Tool trajectory planning with inter-path consistency of feedrate for freeform surface machining","authors":"Shu Wang , Hui Zhang , Bingran Li , Peiqing Ye","doi":"10.1016/j.cirpj.2025.08.003","DOIUrl":"10.1016/j.cirpj.2025.08.003","url":null,"abstract":"<div><div>For CNC machining of freeform surfaces, inter-path inconsistency of feedrate for tool trajectories can lead to surface defects such as overcutting, undercutting, and uneven tool marks, significantly affecting the surface quality of workpieces. However, existing tool trajectory planning methods typically focus only on motion planning for a single toolpath in the feed direction while neglecting the toolpath reference information in the cross-feed direction, which limits the potential improvement in machining quality. To address this issue, a tool trajectory planning method with inter-path consistency of feedrate is proposed in this paper, which includes an inter-path mapping and consistent redistribution algorithm for tool position points, as well as a feedrate planning algorithm based on interpolation between sub-toolpaths. By referring to the position and feedrate information of adjacent sub-toolpaths, the proposed method can achieve a more uniform feedrate distribution in the cross-feed direction. Additionally, to evaluate the effectiveness of the proposed method in optimizing inter-path consistency of feedrate, two evaluation indicators, inter-path feedrate distribution cosine similarity and feedrate gradient in cross-feed direction, are introduced. Simulation and experimental results demonstrate the feasibility and effectiveness of the proposed method, showing that it can significantly improve inter-path consistency of feedrate compared to conventional methods, and finally enhance surface quality and machining efficiency.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"62 ","pages":"Pages 1-15"},"PeriodicalIF":5.4,"publicationDate":"2025-08-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144831479","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}

引用次数: 0

Unraveling stress inheritance and distribution mechanisms in the multi-stage processing of 2219 aluminum alloy tanks 揭示2219铝合金储罐多阶段加工过程中的应力继承与分布机制

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-08-06 DOI: 10.1016/j.cirpj.2025.07.011

Shulin Lu , Jianfeng Wang , Lihong Cheng , Yuhang Duan , Yaobang Zhao , Caiyuan Lin , Junchen Li , Xiaohong Zhan

Controlling residual stress during the multi-stage processing of rocket tanks is pivotal to ensuring the safety and longevity of reusable launch vehicles(RLVs). This study established a multi-stage processing model to simulate the continuous fabrication of the tank, validated experimentally for accuracy. By integrating stress zoning with predefined fields, stress inheritance across processing stages was achieved, facilitating a detailed analysis of stress redistribution and inheritance throughout the tank’s continuous processing. The results reveal that under multi-stage processing, the peak stress in the spun tank bottom undergoes an "increase-decrease-increase" pattern. Following heat treatment, the stress distribution becomes uniform, whereas after welding, stress concentration emerges at the edges and the dome region, reaching a peak stress of 112.7 MPa. For the barrel segment, the overall peak stress follows an "increase-decrease" trend. After roll bending (RB), a high stress zone appears in the middle of the wall panel. After friction stir welding (FSW) of the longitudinal weld, stress concentration occurs at the weld seam, with annular high stress zones forming at both ends. Upon completion of the FSW of the girth weld, thermomechanical effects alleviate the initial stress concentration areas, which gradually shift to the girth weld and adjacent regions. Throughout the multi-stage processing, the peak stress rises from 43.8 MPa to 126.3 MPa. To regulate the tank’s residual stress, orthogonal experiments were utilized to optimize welding parameters, resulting in a 20.8 % reduction in peak stress. These findings provide theoretical support for optimizing the manufacturing process of RLVs.

控制火箭燃料箱多级加工过程中的残余应力是保证可重复使用运载火箭安全性和寿命的关键。本研究建立了一个多阶段加工模型来模拟储罐的连续制造，并通过实验验证了其准确性。通过将应力分区与预定义的域相结合，实现了跨加工阶段的应力继承，便于详细分析整个储罐连续加工过程中的应力重新分布和继承。结果表明：在多段加工过程中，纺丝罐底峰值应力呈现“增大-减小-增大”的变化规律；热处理后应力分布均匀，焊接后边缘和穹顶区域出现应力集中，峰值应力为112.7 MPa。对于桶段，总体峰值应力呈“增加-减少”趋势。轧辊弯曲后，壁板中部出现高应力区。纵向焊缝搅拌摩擦焊后，焊缝出现应力集中，两端形成环形高应力区。在环焊缝FSW完成后，热力学效应缓解了初始应力集中区，应力集中区逐渐向环焊缝及邻近区域转移。在多段加工过程中，峰值应力从43.8 MPa上升到126.3 MPa。通过正交试验对焊接参数进行了优化，得到峰值应力降低20.8%的结果。这些研究结果为优化rlv的制造工艺提供了理论支持。

{"title":"Unraveling stress inheritance and distribution mechanisms in the multi-stage processing of 2219 aluminum alloy tanks","authors":"Shulin Lu , Jianfeng Wang , Lihong Cheng , Yuhang Duan , Yaobang Zhao , Caiyuan Lin , Junchen Li , Xiaohong Zhan","doi":"10.1016/j.cirpj.2025.07.011","DOIUrl":"10.1016/j.cirpj.2025.07.011","url":null,"abstract":"<div><div>Controlling residual stress during the multi-stage processing of rocket tanks is pivotal to ensuring the safety and longevity of reusable launch vehicles(RLVs). This study established a multi-stage processing model to simulate the continuous fabrication of the tank, validated experimentally for accuracy. By integrating stress zoning with predefined fields, stress inheritance across processing stages was achieved, facilitating a detailed analysis of stress redistribution and inheritance throughout the tank’s continuous processing. The results reveal that under multi-stage processing, the peak stress in the spun tank bottom undergoes an \"increase-decrease-increase\" pattern. Following heat treatment, the stress distribution becomes uniform, whereas after welding, stress concentration emerges at the edges and the dome region, reaching a peak stress of 112.7 MPa. For the barrel segment, the overall peak stress follows an \"increase-decrease\" trend. After roll bending (RB), a high stress zone appears in the middle of the wall panel. After friction stir welding (FSW) of the longitudinal weld, stress concentration occurs at the weld seam, with annular high stress zones forming at both ends. Upon completion of the FSW of the girth weld, thermomechanical effects alleviate the initial stress concentration areas, which gradually shift to the girth weld and adjacent regions. Throughout the multi-stage processing, the peak stress rises from 43.8 MPa to 126.3 MPa. To regulate the tank’s residual stress, orthogonal experiments were utilized to optimize welding parameters, resulting in a 20.8 % reduction in peak stress. These findings provide theoretical support for optimizing the manufacturing process of RLVs.</div></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":"61 ","pages":"Pages 524-541"},"PeriodicalIF":5.4,"publicationDate":"2025-08-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144780999","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}

引用次数: 0