Advances in Manufacturing

Review on thermochromic vanadium dioxide based smart coatings: from lab to commercial application

Tian-Ci Chang, Xun Cao, Shan-Hu Bao, Shi-Dong Ji, Hong-Jie Luo, Ping Jin

2018, 6(1): 1-19. doi:10.1007/s40436-017-0209-2

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With an urgent demand of energy efficient coatings for building fenestrations, vanadium dioxide (VO₂)-based thermochromic smart coatings have been widely investigated due to the reversible phase transition of VO₂ at a critical transition temperature of 68 C, which is accompanied by the modulation of solar irradiation, especially in the near-infrared region. As for commercial applications in our daily life, there are still some obstacles for VO₂-based smart coatings, such as the high phase transition temperature, optical properties (luminous transmittance and solar modulation ability), environmental stability in a long-time period, as well as mass production. In this review, recent progress of thermochromic smart coatings to solve above obstacles has been surveyed. Meanwhile, future development trends have also been given to promote the goal of commercial production of VO₂ smart coatings.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-017-0209-2

State of the art of bioimplants manufacturing: part I

Cheng-Wei Kang, Feng-Zhou Fang

2018, 6(1): 20-40. doi:10.1007/s40436-017-0207-4

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Bioimplants are becoming increasingly important in the modern society due to the fact of an aging population and associated issues of osteoporosis and osteoarthritis. The manufacturing of bioimplants involves an understanding of both mechanical engineering and biomedical science to produce biocompatible products with adequate lifespans. A suitable selection of materials is the prerequisite for a long-term and reliable service of the bioimplants, which relies highly on the comprehensive understanding of the material properties. In this paper, most biomaterials used for bioimplants are reviewed. The typical manufacturing processes are discussed in order to provide a perspective on the development of manufacturing fundamentals and latest technologies. The review also contains a discussion on the current measurement and evaluation constraints of the finished bioimplant products. Potential future research areas are presented at the end of this paper.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-017-0207-4

Adiabatic shear fracture prediction in high-speed cutting at various negative rake angles and feeds

Li-Yao Gu, Min-Jie Wang

2018, 6(1): 41-51. doi:10.1007/s40436-018-0212-2

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The critical characteristics of adiabatic shear fracture (ASF) that induce the formation of isolated segment chip in high-speed machining was further investigated. Based on the saturation limit theory, combining with the stress and deformation conditions and the modified Johnson-Cook constitutive relation, the theoretical prediction model of ASF was established. The predicted critical cutting speeds of ASF in high-speed machining of a hardened carbon steel and a stainless steel were verified through the chip morphology observations at various negative rake angles and feeds. The influences of the cutting parameters and thermal-mechanical variables on the occurrence of ASF were discussed. It was concluded that the critical cutting speed of ASF in the hardened carbon steel was higher than that in the stainless steel under a larger feed and a lower negative rake angle. The proposed prediction model of ASF could predict reasonable results in a wide cutting speed range, facilitating the engineering applications in high-speed cutting operations.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0212-2

Comparative investigation towards machinability improvement in hard turning using coated and uncoated carbide inserts: part I experimental investigation

Ramanuj Kumar, Ashok Kumar Sahoo, Purna Chandra Mishra, Rabin Kumar Das

2018, 6(1): 52-70. doi:10.1007/s40436-018-0215-z

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The investigation of low cost uncoated and coated carbide insert in the hard turning of hardened AISI D2 steel (≥55 HRC) will definitely open up a new arena as an economical alternative suitable to industrial machining sectors. Thus, this paper reports the comparative machinability assessment for the hard turning of AISI D2 steel ((55 ±1) HRC) by coated and uncoated carbide insert in a dry environment. Micro hardness and abrasion tests were carried out to assess resistance capability against wear. The above test results confirmed the greater wear resistance ability of Al₂O₃ coated carbide insert over uncoated carbide. Based on the extensive investigation of comparative machinability, the coated carbide insert (TiN-TiCN-Al₂O₃) outperformed the uncoated carbide insert with regard to surface roughness, flank wear, chip-tool interface temperature, and chip morphology. Abrasion and diffusion were observed as the principal tool wear mechanisms in the investigated range. The uncoated carbide failed completely due to the severe chipping and quick dulling of the cutting edge, which led to its unsuitability for machining hardened steel.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0215-z

Additive manufacturing of mechanical testing samples based on virgin poly (lactic acid) (PLA) and PLA/wood fibre composites

Yu Dong, Jamie Milentis, Alokesh Pramanik

2018, 6(1): 71-82. doi:10.1007/s40436-018-0211-3

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3D printing in additive manufacturing is considered as one of key technologies to the future high-precision manufacturing in order to benefit diverse industries in building construction, product development, biomedical innovation, etc. The increasing applications of 3D printed components depend primarily on their significant merits of reduced weight, minimum used materials, high precision and shorter production time. Furthermore, it is very crucial that such 3D printed components can maintain the same or even better material performance and product quality as those achieved by conventional manufacturing methods. This study successfully fabricated 3D printed mechanical testing samples of PLA and PLA/wood fibre composites. 3D printing parameters including infill density, layer height and the number of shells were investigated via design of experiments (DoE), among which the number of shells was determined as the most significant factor for maximising tensile strengths of PLA samples. Further, DoE work evaluated the effect of material type (i.e., neat PLA and PLA/wood fibres) and the number of shells on tensile, flexural and impact strengths of material samples. It is suggested that material type is the only predominant factor for maximising all mechanical strengths, which however are consistently lower for PLA/wood fibre composites when compared with those of neat PLA. Increasing the number of shells, on the other hand, has been found to improve almost all strength levels and decrease infill cavities.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0211-3

Thermal optimization and experimental research of high-speed universal pulverizer

Qiang He, An-Ling Li, Yuan Shen, Li-Li Li

2018, 6(1): 83-94. doi:10.1007/s40436-017-0208-3

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Because of high efficiency, energy conservation, simple operation, wide application range, and small size, the high-speed universal pulverizer has been well received by customers. However, its electrical motor can overheat when working, which hinders continuous operation of the pulverizer. In this study, a series of efforts were made to address this problem. Firstly, a detailed analysis of the working principle of the pulverizer was conducted and an optimization plan was proposed, consisting in punching ventilation holes on the surface of the original pulverizer. Simulations of the pulverizer flow field before and after optimization were performed. The hydrodynamic simulation results were used to conduct a steady state thermal analysis of the pulverizer, investigating the influence of the flow field on heat transfer. Additionally, experimental investigations were conducted on the pulverizer before and after optimization in order to measure and compare the parameters (motor working temperature, wind speed and temperature of the motor cooling system, vibration, noise, and pulverizing degree of the material) influencing the performance of the pulverizer. The numerical simulation results showed an increment in heat transfer caused by increment in air flow volume and velocity when air was injected into the pulverizer through bottom and side holes. Experimental results showed that the pulverizer with air injection through holes had the best performance when temperature, vibration, and refinement effect were considered as performance indicators.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-017-0208-3

Chatter stability prediction in high-speed micromilling of Ti6Al4V via finite element based microend mill dynamics

Kundan K. Singh, Ramesh Singh

2018, 6(1): 95-106. doi:10.1007/s40436-018-0210-4

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High-speed micromilling (spindle speeds 100 000 r/min) can create complex three-dimensional microfeatures in difficult-to-machine materials. The micromachined surface must be of high quality, to meet functional requirements. However, chatter-induced dynamic instability deteriorates the surface quality and can be detrimental to tool life. Chatter-free machining can be accomplished by identifying stable process parameters via stability lobe diagram. To generate accurate stability lobe diagram, it is essential to determine the microend mill dynamics. Frequency response function is required to determine the tooltip dynamics obtained by experimental impact analysis. Note that application of impact load at the microend mill tip (typically 100-500 μm) is not feasible as it would invariably end with tool failure. Consequently, alternative methods need to be developed to identify the microend mill dynamics. In the present work, the frequency response function for the microend mill is obtained by finite element method modal analysis. The frequency response function obtained from modal analysis has been verified from the experimentally obtained frequency response function. The experimental frequency response function was obtained by impacting the microend mill near the taper portion with an impact hammer and measuring the vibration of the tool-tip with a laser displacement sensor. The fundamental frequency obtained from finite element method modal analysis shows a difference of 6.6% from the experimental fundamental frequency. Microend mill dynamics obtained from the finite element method is used for chatter prediction in high-speed micromilling operations. The stability lobe diagram predicts the stability boundary accurately at 60 000 r·min^-1 and 80 000 r/min; however, a slight deviation is observed at 100 000 r/min.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0210-4

Microstructure evolution of Al-Si-10Mg in direct metal laser sintering using phase-field modeling

Jyotirmoy Nandy, Hrushikesh Sarangi, Seshadev Sahoo

2018, 6(1): 107-117. doi:10.1007/s40436-018-0213-1

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Direct metal laser sintering (DMLS) has evolved as a popular technique in additive manufacturing, which produces metallic parts layer-by-layer by the application of laser power. DMLS is a rapid manufacturing process, and the properties of the build material depend on the sintering mechanism as well as the microstructure of the build material. Thus, the prediction of part microstructures during the process may be a key factor for process optimization. In addition, the process parameters play a crucial role in the microstructure evolution, and need to be controlled effectively. In this study, the microstructure evolution of Al-Si-10Mg alloy in DMLS process is studied with the help of the phase field modeling. A MATLAB code is used to solve the phase field equations, where the simulation parameters include temperature gradient, laser power and scan speed. From the simulation result, it is found that the temperature gradient plays a significant role in the evolution of microstructure with different process parameters. In a single-seed simulation, the growth of the dendritic structure increases with the increase in the temperature gradient. When considering multiple seeds, the increasing in temperature gradients leads to the formation of finer dendrites; however, with increasing time, the dendrites join and grain growth are seen to be controlled at the interface.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0213-1

Tracking and localization for omni-directional mobile industrial robot using reflectors

Shuai Guo, Ting-Ting Fang, Tao Song, Feng-Feng Xi, Bang-Guo Wei

2018, 6(1): 118-125. doi:10.1007/s40436-018-0216-y

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In this paper, an improved tracking and localization algorithm of an omni-directional mobile industrial robot is proposed to meet the high positional accuracy requirement, improve the robot's repeatability positioning precision in the traditional trilateral algorithm, and solve the problem of pose lost in the moving process. Laser sensors are used to identify the reflectors, and by associating the reflectors identified at a particular time with the reflectors at a previous time, an optimal triangular positioning method is applied to realize the positioning and tracking of the robot. The experimental results show that positioning accuracy can be satisfied, and the repeatability and anti-jamming ability of the omni-directional mobile industrial robot will be greatly improved via this algorithm.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0216-y

Production line 3D visualization monitoring system design based on OpenGL

Jian-Fei Chai, Xiao-Mei Hu, He-Wei Qu, Ming-Hang Li, Hui-Jing Xu, Yu Liu, Tao Yu

2018, 6(1): 126-135. doi:10.1007/s40436-018-0217-x

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New production line management technologies are required and adopted recently with the development of modern manufacturing industry. In this study, a production line three-dimensional (3D) visualization monitoring system based on OpenGL modeling, open database connectivity (ODBC), and database management technology is established on a VC++6.0 platform to satisfy effective production. A client/server model is adopted in the system, and data on processing information, interactive operation, and failure process are stored in the server side database. A client reads the workpiece process information from the server, and the machining process of every workpiece is visually represented in the form of 3D visualization. Production line 3D visualization provides production capacity simulation to optimize the parameter settings. When compared with the analysis results of production line capacity, the key parameters possess the same optimal values, and this proves the accuracy of production line 3D visualization monitoring system. The system provides effective data support for production line monitoring and management in enterprises.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0217-x

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