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2024年 第12卷 第4期    刊出日期：2024-12-06

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Design and fabrication of an aluminium oxide cutting insert with an internal cooling channel

John O'Hara, Feng-Zhou Fang

2024, 12(4):  619-641.  doi:10.1007/s40436-024-00483-3

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This paper presents the design and fabrication of an aluminium oxide cutting insert with an internal cooling channel formed through an additive manufacturing method. The formed insert is subjected to a controlled densification process and analysed through a series of characterisation investigations. The purpose of the study is to develop the design concept and analyse the forming and sintering parameters used in the lithographic ceramic manufacturing process. The results validated the feasibility of the geometrical design, providing the required structural conformity with the integrated internal feature using conditional specifications. It is confirmed that the forming parameters would affect the material properties of the green body. Furthermore, the results indicate that the heating rate and temperature variance of the de-binding and thermal treatment regime influences the microstructural growth kinetics and the quality of the densified insert. Using a novel application of liquid gallium as an internal coolant, experimental results showed a decrease in tool wear difference of 36% at V_c=250 m/min, and 31% in tool wear difference at V_c=900 m/min between cooling and non-cooling conditions. When external cooling was applied, the results showed at V_c=250 m/min, the difference between the tool wear rates with the internal coolant relative to the external coolant was 29%. Increasing to V_c=900 m/min, the results revealed a 16% tool wear difference. The results clearly indicate the potential of liquid gallium as a heat transfer agent in internal cooling applications for cutting inserts, and by extension demonstrable reduction in tool wear.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00483-3

Research progress of magnetorheological polishing technology: a review

Ming-Ming Lu, Ya-Kun Yang, Jie-Qiong Lin, Yong-Sheng Du, Xiao-Qin Zhou

2024, 12(4):  642-678.  doi:10.1007/s40436-024-00490-4

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As an essential link in ultra-precision machining technology, various new surface polishing technologies and processes have always attracted continuous in-depth research and exploration by researchers. As a new research direction of ultra-precision machining technology, magnetorheological polishing technology has become an important part. The polishing materials and magnetorheological fluids involved in the process of magnetorheological polishing are reviewed. The polishing principle, equipment development, theoretical research and process research of magnetorheological polishing technologies, such as the wheel-type, cluster-type, ball-type, disc-type and other types, derived from the magnetorheological polishing process, are reviewed. The above magnetorheological polishing technologies are analyzed and compared from the perspective of processing accuracy, processing efficiency and application range. The curvature adaptive magnetorheological polishing technology with a circulatory system is proposed to achieve high efficiency and high-quality polishing.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00490-4

Quality control in multistage machining processes based on a machining error propagation event-knowledge graph

Hao-Liang Shi, Ping-Yu Jiang

2024, 12(4):  679-697.  doi:10.1007/s40436-024-00481-5

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In multistage machining processes (MMPs), a clear understanding of the error accumulation, propagation, and evolution mechanisms between different processes is crucial for improving the quality of machining products and achieving effective product quality control. This paper proposes the construction of a machining error propagation event-knowledge graph (MEPEKG) for quality control in MMPs, inspired by the application of knowledge graphs to data, information, and knowledge organization and utilization. Initially, a cyber-physical system (CPS)-based production process data acquisition sensor network is constructed, and process flow-oriented process monitoring is achieved through the radio frequency identification (RFID) production event model. Secondly, the process-related quality feature and working condition data are preprocessed; features are extracted from the distributed CPS nodes; and the production event model is used to achieve the dynamic mapping and updating of feature data under the guidance of the MEPEKG schema layer. Moreover, the mathematical model of machining error propagation based on the second-order Taylor expansion is used to quantitatively analyze the quality control in MMPs based on the support of MEPEKG data. Finally, the efficacy and reliability of the MEPEKG for error propagation analysis and quality control of MMPs were verified using a case study of a specially shaped rotary component.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00481-5

Multi-factor integrated configuration model and three-layer hybrid optimization algorithm framework: turnkey project-oriented rapid manufacturing system configuration

Shu-Lian Xie, Feng Xue, Wei-Min Zhang, Jia-Wei Zhu, Zi-Wei Jia

2024, 12(4):  698-725.  doi:10.1007/s40436-023-00476-8

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In the context of increasingly prominent product personalization and customization trends, intelligent manufacturing-oriented turnkey projects can provide manufacturers with fast and convenient turnkey services for manufacturing systems. Their key characteristic is the transformation of the traditional design process into a configuration process. However, the scope of configuration resources in existing research is limited; the cost and time required for manufacturing system construction are overlooked; and the integration of the system layout configuration is rarely considered, making it difficult to meet the manufacturing system configuration requirements of turnkey projects. In response, this study establishes a multi-factor integrated rapid configuration model and proposes a solution method for manufacturing systems based on the requirements of turnkey projects. The configuration model considers the system construction cost and duration and the product manufacturing cost and duration, as optimization objectives. The differences in product feature-dividing schemes and configuration of processes, equipment, tools, fixtures, and layouts were considered simultaneously. The proposed model-solving method is a three-layer hybrid optimization algorithm framework with two optimization algorithm modules and an intermediate algorithm module. Four hybrid configuration algorithms are established based on non-dominated sorting genetic algorithm-III (NSGAIII), non-dominated sorting genetic algorithm-II (NSGAII), multi-objective simulated annealing (MOSA), multi-objective neighborhood search (MONS), and tabu search (TS). These algorithms are compared and validated through a hydraulic valve block production case, and the TS and NSGAIII (TS-NSGAIII) hybrid algorithm exhibits the best performance. This case demonstrates the effectiveness of the proposed model and solution method.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00476-8

Programming time-dependent behavior in 4D printing by geometric and printing parameters

Yi-Cong Gao, Dong-Xin Duan, Si-Yuan Zeng, Hao Zheng, Li-Ping Wang, Jian-Rong Tan

2024, 12(4):  726-741.  doi:10.1007/s40436-024-00489-x

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Smart structures realize sequential motion and self-assembly through external stimuli. With the advancement of four-dimensional (4D) printing, the programming of sequential motions of smart structures is endowed with more design and manufacturing possibilities. In this research, we present a method for physically programming the timescale of shape change in 4D-printed bilayer actuators to enable the sequential motion and self-assembly of smart structures. The effects of the geometric and printing parameters on the time-dependent behavior of 4D-printed bilayer actuators are investigated. The results show that the thickness of the active layer directly affects the timescale of motion, and increasing the thickness leads to faster motion until the thickness ratio is close to 4:6. Similarly, a higher printing speed results in faster motion. Conversely, a higher printing temperature and a greater layer height result in a slower shape change. The effects of the length-width ratio, line width, and filling ratio on the timescale of motion are not as straightforward. Finally, we demonstrate several smart structures that exhibit sequential motion, including a labyrinth-like self-folding structure that is choreographed to achieve multi-step self-shaping and a flower-shaped structure where each part completes its movement sequentially to avoid collisions. The presented method extends the programmability and functional capabilities of 4D printing.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00489-x

Single-track geometrical characteristics under different energy input and mass addition in coaxial laser cladding

Yan-Hua Bian, Chong-Xin Tian, Bo Chen, Bin-Xin Dong, Shao-Xia Li, Zhi-Yong Li, Yang-Rui Nan, Xiu-Li He, Gang Yu

2024, 12(4):  742-763.  doi:10.1007/s40436-023-00478-6

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To provide a broad processing window with a high deposition rate, a comprehensive analysis of single-track geometrical characteristics over a wide range of laser energies and mass inputs in laser cladding is necessary. The formation of a single cladding track of Inconel 718 on a substrate by coaxial laser cladding, with a wide range of laser power from 1 200 W to 3 900 W and a powder feeding rate from 5 g/min to 35 g/min, was studied from both theoretical and experimental points of view. A quantitative model of powder concentration distribution was developed based on the powder transport morphology obtained by high-speed photography. Linear regression models were established between nine geometrical characteristics and the combined process parameters of laser power and powder feeding rate, written as P^αF^β, to quantitatively analyze the geometrical characteristics of the clad. These were confirmed by large correlation coefficients and analysis of residuals. From the findings we deduced that more energy input enhanced the outward direction of Marangoni convection, leading to the melt pool undergoing evolution from shallow dilution and flat dilution to fluctuating dilution. An almost linear relationship was found between the cladding width, W, and the laser power, indicating that laser energy accumulation was a major factor in the evolution of W. The increase ratio of the cladding height, h_c, ranged from 640% to 360% along with an increase in the powder feeding rate, implying that the evolution of h_c, was dominated by the powder feeding rate. The total area of the cross-section, A; the area of the clad, A_c; the area of the molten substrate, A_m; the total height of the cross-section, H; the penetration depth, h_m; the dilution ratio, D; and the wetting angle, θ, were determined by a complex coupling of energy input and mass accumulation, and they are proportional to P^0.5F^0.2, P^0.2F^0.5, P^0.5/F^0.2, P^0.3F, P^0.5/F^0.2, P^0.2/F^0.2, and P^0.2/F^0.2, respectively. This research aims to provide general knowledge on the influence of energy input and mass addition on the geometrical characteristics of the clad and its related influence mechanism. Such information could provide a reference and basis for promoting the practical application of laser cladding technology.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00478-6

Holorailway: an augmented reality system to support assembly operations in the railway industry

Clara Garcia, Mario Ortega, Eugenio Ivorra, Manuel Contero, Pau Mora, Mariano L. Alcañiz

2024, 12(4):  764-783.  doi:10.1007/s40436-023-00479-5

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During the last two decades, industrial applications of augmented reality (AR) have been incorporated in sectors such as automotive or aeronautics in tasks including manufacturing, maintenance, and assembly. However, AR’s potential has yet to be demonstrated in the railway sector due to its complexity and difficulties in automating tasks. This work aims to present an AR system based on HoloLens 2 to assist the assembly process of insulation panels in the railway sector significantly decreasing the time required to perform the assembly. Along with the technical description of the system, an exhaustive validation process is provided where the assembly using the developed system is compared to the traditional assembly method as used by a company that has facilitated a case study. The results obtained show that the system presented outperforms the traditional solution by 78% in the time spent in the localization subtask, which means a 47% decrease in the global assembly time. Additionally, it decreases the number of errors in 88% of the cases, obtaining a more precise and almost error-free assembly process. Finally, it is also proven that using AR removes the dependence on users’ prior knowledge of the system to facilitate assembly.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00479-5

Sustainable direct metallization of 3D-printed metal-infused polymer parts: a novel green approach to direct copper electroless plating

Javid Sharifi, Vlad Paserin, Haniyeh (Ramona) Fayazfar

2024, 12(4):  784-797.  doi:10.1007/s40436-024-00486-0

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Metallization, which is coating metals on the surface of objects, has opened up new possibilities for lightweight structures while integrating polymer and metal features. Electroless plating is a potential method for metalizing plastic 3D-printed parts; however, conventional approaches rely on pre-surface activation and catalyzation with expensive metal catalysts and hazardous acids. To address these issues, the current study represents a novel eco-friendly and low-cost approach for direct metallization of non-conductive 3D-printed parts, without using hazardous, toxic, and expensive conventional pre-treatments. Using the developed methodology, we electrolessly copper plated polymer-copper infused 3D-printed part as well as plastic components for the first time, directly. We initiated and implemented the idea of exposing the copper particles embedded in the polymer to the surface of copper-polymer parts by applying a sustainable mechanical or chemical method to make the surface conductive and ready for direct plating. A formaldehyde-free (green) electroless copper solution was developed in-house in addition to skipping conventional etching pre-treatment using harmful chemicals, making this a real step forward in the sustainable metallization of 3D-printed parts. In this study, the mechanical properties of copper-polylactic acid (PLA) 3D-printed parts revealed a 65% reduction in tensile strength and 63% increase in tensile modulus, compared to virgin PLA. Furthermore, the morphological characterization of the copper coated 3D-printed parts showed a homogeneous copper coating on the surface after direct electroless plating, with a plating rate of 7.5 μm/h. Allowing complex and functional devices printed in this manner to be quickly metalized without modification using toxic and costly solutions is a significant advancement in lowering the cost and manufacturing complexity of 3D-printed parts, increasing efficiencies, and lowering weight, and thus is a game changer in the technology’s adoption.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00486-0

Study of atomized discharge ablation-chemical composite machining of SiCp/Al

Xiu-Lei Yue, Zhi-Dong Liu, Shun-Cheng Zhou, Zi-Long Feng

2024, 12(4):  798-809.  doi:10.1007/s40436-023-00480-y

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Electrical discharge-induced ablation machining utilizes the significant chemical energy released by the combustion of oxygen with metals to remove materials, thereby greatly enhancing the material removal rate (MRR). However, in the case of discharge ablation machining of silicon carbide particle-reinforced aluminum matrix composites (SiCp/Al), the effect of oxygen can easily result in the formation of poorly conductive oxides, which in turn affect the machining stability and adversely impact the MRR and quality of the machining surface. To address this problem, this study proposes the use of sodium carbonate (Na₂CO₃) solution as the atomization medium to chemically dissolve the oxide during processing to achieve the effect of atomized discharge ablation-chemical composite processing. The study found that the Na₂CO₃ solution facilitated high-temperature chemical etching behavior in the SiCp/Al atomized discharge ablation process. The Na₂CO₃ solution reacted chemically with and etched away the recalcitrant oxide that formed in the SiCp/Al process area during machining, thereby ensuring efficient and continuous electrical discharge ablation machining. We applied the atomized discharge ablation-chemical composite machining method to mill SiCp/Al. The experimental results showed that the MRR was 2.66 times higher than that of electrical discharge machining (EDM) and 1.98 times higher than that of conventional atomized discharge ablation milling. Moreover, the relative electrode wear ratio was reduced by 76.01% compared with that of EDM and 82.30% compared with that of conventional atomized discharge ablation machining.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00480-y

Fabrication of micro holes using low power fiber laser: surface morphology, modeling and soft-computing based optimization

Tuhin Kar, Swarup S. Deshmukh, Arjyajyoti Goswami

2024, 12(4):  810-831.  doi:10.1007/s40436-024-00484-2

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Fiber laser micromachining is found extensive applications at industrial level because it is cheap and simple to use. Due to its high strength and low conductivity titanium is difficult to machine with conventional methods. In this investigation, micro holes were fabricated using a 30 W fiber laser on 2 mm thick α-titanium (Grade 2) and the process parameters were optimized through response surface methodology (RSM) and teaching learning-based optimization (TLBO) approach. Experimental runs were designed as per rotatable central composite design (RCCD). Material removal rate (MRR), hole circularity (HC), deviation in diameter (DEV) and heat affected zone (HAZ) were selected as output. A third-order polynomial prediction model was established using RSM. Analysis of variance (ANOVA) suggested that the developed model was 93.5% accurate. The impact of input factors on responses were studied by 3D surface plots. RSM desirability indicates that optimum micro drilling conditions are scan speed 275.43 mm/s, frequency 24.61 kHz, power 36.23% and number of passes 49.75. TLBO indicates that optimum micro drilling conditions are scan speed 100 mm/s, frequency 20 kHz, power 20% and number of passes 50. Comparison between RSM and TLBO suggested that TLBO provided better optimization results. Surface morphology of the fabricated micro holes were analyzed with scanning electron microscopy (SEM).

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00484-2