CIRP Journal of Manufacturing Science and Technology最新文献_第8页

Integrated vision-based in-line surface defect detection system for realizing zero-defect manufacturing of tapered rollers 集成视觉在线表面缺陷检测系统，实现圆锥滚子零缺陷制造

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-11-06 DOI: 10.1016/j.cirpj.2025.10.009

Swarit Anand Singh, K.A. Desai

Achieving Zero Defect Manufacturing (ZDM) during the mass production of critical components, such as tapered rollers, requires 100% in-line inspection to ensure the supply of defect-free products to consumers. Integrating vision systems with the production line can enable 100% in-line surface inspection of mass-manufactured components, facilitating the realization of ZDM. This work presents a vision-based system designed for integration with a tapered roller production line to detect surface defects. The system features indigenously designed hardware elements for in-line image acquisition, a hybrid algorithm combining image processing and deep learning to detect defective rollers, and seamless synchronization with the production line through an interactive user interface. The image acquisition hardware comprises a single-camera system and a horizontal belt conveyor for controlled translation and rotation of tapered rollers. The image processing framework encompasses algorithms for Region of Interest (ROI) detection, noise removal, and Convolutional Neural Network (CNN)-based surface defect detection, enabling robust prediction capabilities. The developed system is comprehensively evaluated through a performance analysis and Strengths, Weaknesses, Opportunities, and Threats (SWOT) assessment. The outcomes of the present study demonstrate that the vision-based system can be effectively integrated with the tapered roller manufacturing line to achieve reliability and efficacy during in-line inspections. The study also demonstrated that vision-based inspection systems can be implemented to achieve ZDM, enabling manufacturing industries to improve product quality and enhance global competitiveness.

实现零缺陷制造（Zero Defect Manufacturing， ZDM）在锥度滚子等关键部件的批量生产中，需要100%的在线检测，以确保向消费者提供无缺陷的产品。将视觉系统与生产线集成，可实现批量生产部件的100%在线表面检测，促进ZDM的实现。这项工作提出了一个基于视觉的系统，旨在与圆锥辊生产线集成，以检测表面缺陷。该系统具有自主设计的用于在线图像采集的硬件元素，结合图像处理和深度学习的混合算法来检测有缺陷的滚筒，并通过交互式用户界面与生产线无缝同步。图像采集硬件包括单摄像机系统和用于控制锥形滚筒的平移和旋转的水平带式输送机。图像处理框架包括感兴趣区域（ROI）检测、噪声去除和基于卷积神经网络（CNN）的表面缺陷检测算法，实现了强大的预测能力。通过性能分析和优势、劣势、机会和威胁（SWOT）评估，对开发的系统进行全面评估。研究结果表明，基于视觉的系统可以有效地与锥辊生产线集成，以实现在线检测的可靠性和有效性。该研究还表明，基于视觉的检测系统可以实现ZDM，使制造业提高产品质量，增强全球竞争力。

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引用次数: 0

A machining zone contour-based method of automatic 3D process model generation 一种基于加工区域轮廓的三维工艺模型自动生成方法

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-11-14 DOI: 10.1016/j.cirpj.2025.11.003

Wei Yang , Xiaogang Wang , Yuewei Bai , Xinlin Zhou , Jianwei Song , Hua Mu

The 3D process model of a part is a series of solid models that reflect the process of transforming a blank into a finished part through specific machining steps. The rapid and automated generation of 3D process models is essential for establishing the digital thread that seamlessly integrates data, models, and processes across the entire product lifecycle. Traditional process models are typically created manually or generated as the by-products of CAM outputs. These approaches are inefficient, prone to errors, and often disconnected from the process route, which further widens the digital divide across various stages of the product lifecycle. To address these issues, this paper proposed a method for generating 3D process models based on machining zone contour. First, based on the part model and the manufacturing process specifications, the machining zones of each machining step are identified as the Boolean difference between the blank model and the corresponding cutting bodies for that step. Next, following the hierarchical decomposition of the machining zones, the corresponding machining zone contours are derived from the geometric structure and material boundaries of each individual machining zone. Finally, these contours are employed in simple modeling operations to construct the cutting bodies, thereby enabling the automatic and rapid generation of process models. Case studies show that, compared with existing methods, the proposed approach improves process model generation efficiency by more than 37 %, ensures high accuracy through strong consistency with process planning, and is applicable to both rotationally and non-rotationally machining parts. In digital manufacturing, this method can provide models for CAM toolpath and subsequent production guidance, thereby facilitating the integration of CAD, CAPP, and CAM.

零件的三维工艺模型是反映毛坯通过特定加工步骤转化为成品零件过程的一系列实体模型。3D工艺模型的快速和自动化生成对于在整个产品生命周期中建立无缝集成数据、模型和工艺的数字线程至关重要。传统的流程模型通常是手动创建的，或者作为CAM输出的副产品生成的。这些方法效率低下，容易出错，并且经常与工艺路线脱节，这进一步扩大了产品生命周期各个阶段的数字鸿沟。针对这些问题，提出了一种基于加工区域轮廓的三维加工模型生成方法。首先，根据零件模型和制造工艺规范，将各加工步骤的加工区域识别为该步骤的毛坯模型与相应切削体之间的布尔差；然后，根据加工区域的几何结构和材料边界对加工区域进行分层分解，得到相应的加工区域轮廓。最后，利用这些轮廓进行简单的建模操作来构造切割体，从而实现过程模型的自动快速生成。实例研究表明，与现有方法相比，该方法的工艺模型生成效率提高了37% %以上，与工艺规划一致性强，精度高，适用于旋转和非旋转加工零件。在数字化制造中，该方法可以为CAM的刀具轨迹和后续的生产指导提供模型，从而促进CAD、CAPP和CAM的集成。

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引用次数: 0

Interpretable generative machine learning model based in-situ process monitoring in robotic wire arc based directed energy deposition of aluminum alloys 基于可解释生成机器学习模型的机器人电弧铝合金定向能沉积原位过程监测

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-09-23 DOI: 10.1016/j.cirpj.2025.08.010

Deepak Kumar, Sunil Jha

WA-DED using CMT is emerging as a high-throughput metal AM strategy, yet it remains susceptible to a variety of thermomechanical instabilities and metallurgical discontinuities. In this study, we present an advanced AE based in-situ monitoring utilizing the generative ML framework to robustly detect and characterize anomalous conditions that compromise part integrity. Specifically, we examine five critical fault scenarios which are overcurrent, high travel speed, insufficient shielding gas flow, combination of overcurrent and low shielding gas flow rate and combination of high travel speed and low shielding gas flow rate elucidate their distinct signatures in the acoustic domain. A rigorous selection of time and frequency domain descriptors is leveraged to train the variational autoencoder, enabling accurate reconstruction of normal process states and efficient outlier detection. Microstructural analyses, encompassing FESEM, Micro-CT, and XRD, validate the detrimental influence of these faults on porosity evolution, grain morphology, and mechanical properties such as UTS. The proposed VAE model demonstrated robust performance across multiple defect types, achieving peak detection accuracies of 87% for overcurrent-induced faults, 85% for high travel speed anomalies, 81% for defects caused by insufficient shielding gas flow, 87% for combined effect of overcurrent and low gas flow rate, and 84% for combined effect of high travel speed and low gas flow rate. Overcurrent anomalies induce coarse columnar grains and high porosity content, while high travel speed amplifies geometric irregularities. Low gas flow conditions foster oxidation induced porosity. The proposed approach achieves high fidelity in detection of these defects, underscoring the synergy between data driven reconstruction errors and material characterization. By integrating unsupervised generative deep learning with domain specific interpretability through feature sensitivity analysis, this acoustic monitoring paradigm provides a scalable and cost effective pathway to detect defects and ensure structural reliability in WA-DED manufactured components. The comprehensive experimental validations and multi-physics correlational insights position this framework as a robust framework for in-situ process monitoring in WA-DED.

使用CMT的WA-DED正在成为一种高通量金属AM策略，但它仍然容易受到各种热机械不稳定性和冶金不连续的影响。在这项研究中，我们提出了一种先进的基于声发射的原位监测，利用生成式ML框架来鲁棒地检测和表征损害部件完整性的异常情况。具体来说，我们研究了过流、高行程速度、保护气体流量不足、过流和低保护气体流量组合以及高行程速度和低保护气体流量组合五种临界故障场景，阐明了它们在声学领域的不同特征。一个严格的时间和频域描述符的选择被用来训练变分自编码器，使正常过程状态的准确重建和有效的离群检测。微观结构分析，包括FESEM， Micro-CT和XRD，验证了这些断层对孔隙演化，晶粒形貌和力学性能（如UTS）的不利影响。所提出的VAE模型在多种缺陷类型中表现出稳健的性能，对过流引起的故障的峰值检测准确率为87%，对高行程速度异常的峰值检测准确率为85%，对保护气体流量不足引起的缺陷的峰值检测准确率为81%，对过流和低气体流量联合作用的峰值检测准确率为87%，对高行程速度和低气体流量联合作用的峰值检测准确率为84%。过流异常导致粗柱状晶粒和高孔隙率，而高流速放大了几何不规则性。低气体流量条件促进氧化引起的孔隙度。所提出的方法在检测这些缺陷方面实现了高保真度，强调了数据驱动的重构误差和材料表征之间的协同作用。通过特征敏感性分析，将无监督生成深度学习与领域特定可解释性相结合，这种声学监测范式提供了一种可扩展且经济有效的途径来检测WA-DED制造组件的缺陷并确保结构可靠性。综合实验验证和多物理场相关见解使该框架成为WA-DED现场过程监测的强大框架。

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引用次数: 0

Combining generalized fault trees and k-LSTM ensembles for enhancing prognostics and health management 结合广义故障树和k-LSTM集成来增强预测和健康管理

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-11-12 DOI: 10.1016/j.cirpj.2025.11.002

P. Nunes , J. Santos , E. Rocha

Accurately predicting the remaining useful life (RUL) is essential for effective prognostics and health management, enabling optimal maintenance scheduling. However, the black-box nature of many deep learning models hinders their adoption by maintenance practitioners. This study presents k-LSTM-GFT, a novel hybrid framework that integrates automated data-driven generalized fault tree (GFT) construction with a k-fold ensemble of LSTM models to enhance both interpretability and prediction accuracy. Unlike prior work, our method automatically constructs fault trees from sensor data, simultaneously enabling interpretable failure pathway analysis and enriching temporal features for RUL estimation, a unified integration that constitutes a key contribution of this work. Experimental results on benchmark datasets (C-MAPSS and N-CMAPSS) show that k-LSTM-GFT outperforms state-of-the-art models, reducing RMSE by over 18% in multi-fault scenarios. Validation on a real-world injection molding machine dataset further confirms its industrial applicability. By combining model transparency with robust performance, k-LSTM-GFT offers a practical solution tailored to the needs of maintenance practitioners.

准确预测剩余使用寿命（RUL）对于有效预测和健康管理至关重要，从而实现最佳维护计划。然而，许多深度学习模型的黑箱特性阻碍了维护从业者采用它们。本文提出了一种新的混合框架——k-LSTM-GFT，该框架将自动数据驱动的广义故障树（GFT）构建与LSTM模型的k-fold集成相结合，以提高可解释性和预测精度。与之前的工作不同，我们的方法从传感器数据自动构建故障树，同时实现可解释的故障路径分析并丰富RUL估计的时间特征，这是构成本工作关键贡献的统一集成。在基准数据集（C-MAPSS和N-CMAPSS）上的实验结果表明，k-LSTM-GFT优于最先进的模型，在多故障场景下将RMSE降低了18%以上。在实际注塑机数据集上的验证进一步证实了其工业适用性。通过将模型透明度与强大的性能相结合，k-LSTM-GFT提供了适合维护从业者需求的实用解决方案。

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引用次数: 0

Free abrasive assisted magnetorheological polishing: Device design and processing performance analysis 游离磨料辅助磁流变抛光：装置设计及加工性能分析

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-09-24 DOI: 10.1016/j.cirpj.2025.09.015

Yakun Yang, Mingming Lu, Jieqiong Lin, Yongsheng Du

The processing stability and properties of magnetorheological polishing device (MPD) play a crucial role in the processing of optical materials. In this study, a novel MPD was developed to improve the processing stability and properties. The device uses free abrasives to assist in magnetorheological polishing, and completes the self-sharpening of the abrasives in flexible pad using a dynamic magnetic field. This paper presents the principles and structures design involved. The mechanical characteristics of main components and magnetic field characteristics of a Halbach array were analyzed. Based on the developed device, the stability is studied. The advantages of free abrasive assisted magnetorheological polishing method were investigated. The results indicate that the structural design of the main components is reasonable. A dynamic magnetic field device can achieve greater changes in magnetic field intensity and gradient with fewer magnets. It exhibits excellent magnetic field properties. The results obtained by marathon experiment under the same parameters are all distributed within 95 % confidence interval. The processing stability of the MPD was verified. The method can effectively improve the processing performance and has certain advantages. Compared with the traditional magnetorheological polishing method, the processing efficiency can be improved by more than 29.68 %.

磁流变抛光装置（MPD）的加工稳定性和性能在光学材料加工中起着至关重要的作用。在本研究中，开发了一种新型MPD，以提高加工稳定性和性能。该装置利用游离磨料辅助磁流变抛光，利用动态磁场完成柔性垫内磨料的自锐化。本文介绍了所涉及的原理和结构设计。分析了哈尔巴赫阵列主要元件的力学特性和磁场特性。基于所研制的装置，对其稳定性进行了研究。研究了游离磨料辅助磁流变抛光方法的优点。结果表明，主要部件的结构设计是合理的。动态磁场装置可以用更少的磁体实现更大的磁场强度和梯度变化。它具有优异的磁场性能。相同参数下的马拉松试验结果均分布在95% %置信区间内。验证了MPD的加工稳定性。该方法能有效提高加工性能，具有一定的优势。与传统的磁流变抛光方法相比，加工效率可提高29.68 %以上。

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引用次数: 0

Step-dependent machining uncertainty modeling for the process route and application in the machining of the ring-gear 工艺路线的步进不确定性建模及其在环齿加工中的应用

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-09-23 DOI: 10.1016/j.cirpj.2025.09.011

Yanan Zhao, Shaoming Yao

This paper proposes a step-dependent machining uncertainty modeling method for the process routes. With the between-step interaction, the process route integrity is accurately interpreted and all error sources in the production environment are involved in, including the workpiece positioning surface, machine positioning surface, cutter kinetics, workpiece kinetics, clamping force, cutting force, environmental factors, residual stress distortion, heat treatment distortion, and coating/plating variations. The machining uncertainty model shows that the machining uncertainty consists of both regenerated and inherited uncertainties. The proposed modeling method can evaluate a process route in terms of its error source impact on workpiece accuracy. A herringbone gear ring is used to demonstrate its effectiveness as a case study, where an uncertainty model is developed for the full process route, and the process route is assessed before the costly process trial. The process number is reduced from 18 to 15 without affecting the final workpiece accuracy. The experiment shows a good agreement with the uncertainty model results.

提出了一种基于步进的加工路线不确定性建模方法。通过步骤间的交互作用，可以准确地解释工艺路线的完整性，并涉及生产环境中的所有误差源，包括工件定位面、机床定位面、刀具动力学、工件动力学、夹紧力、切削力、环境因素、残余应力变形、热处理变形和涂层/电镀变化。加工不确定性模型表明，加工不确定性包括再生不确定性和继承不确定性。所提出的建模方法可以根据误差源对工件精度的影响来评估工艺路线。以人字齿环为例，建立了整个工艺路线的不确定性模型，并在昂贵的工艺试验前对工艺路线进行了评估。在不影响最终工件精度的情况下，工序数从18个减少到15个。实验结果与不确定性模型的计算结果吻合较好。

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引用次数: 0

Bottom-up segmentation of composite structures for cost-efficient manufacturing 自下而上的复合材料结构分割，以实现成本效益制造

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-09-16 DOI: 10.1016/j.cirpj.2025.08.011

Ádám Ipkovich , Alex Kummer , Balázs Fodor , Gergely Erdős , László Takács , János Abonyi

This work focuses on optimizing manufacturing processes for composite products with complex geometry. The goal is to efficiently partition the 3D surface mesh so that parts can be manufactured with specific technologies while minimizing costs. For this purpose, the proposed algorithm merges the elementary units iteratively by selecting the two elements that reduce the total cost through a bottom-up hierarchical clustering algorithm. The applicability of the method is demonstrated in a case study of bus manufacturing. The results illustrate how the costs of tools, adhesives, and materials vary when a complex structure is segmented.

这项工作的重点是优化复杂几何形状的复合材料产品的制造工艺。目标是有效地划分3D表面网格，以便零件可以用特定的技术制造，同时最大限度地降低成本。为此，该算法通过自底向上的分层聚类算法，选择两个降低总成本的元素，迭代合并基本单元。以客车制造为例，验证了该方法的适用性。结果表明，当复杂结构被分割时，工具、粘合剂和材料的成本是如何变化的。

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 : 2025-11-01 Epub 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。

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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 : 2025-11-01 Epub 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。

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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 : 2025-11-01 Epub 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。

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引用次数: 0