Table of Content

25 June 2019, Volume 7 Issue 2

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ARTICLES

Hybrid genetic algorithm for a type-II robust mixed-model assembly line balancing problem with interval task times

Jia-Hua Zhang, Ai-Ping Li, Xue-Mei Liu

2019, 7(2):  117-132.  doi:10.1007/s40436-019-00256-3

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The type-Ⅱ mixed-model assembly line balancing problem with uncertain task times is a critical problem. This paper addresses this issue of practical significance to production efficiency. Herein, a robust optimization model for this problem is formulated to hedge against uncertainty. Moreover, the counterpart of the robust optimization model is developed by duality. A hybrid genetic algorithm (HGA) is proposed to solve this problem. In this algorithm, a heuristic method is utilized to seed the initial population. In addition, an adaptive local search procedure and a discrete Levy flight are hybridized with the genetic algorithm (GA) to enhance the performance of the algorithm. The effectiveness of the HGA is tested on a set of benchmark instances. Furthermore, the effect of uncertainty parameters on production efficiency is also investigated.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00256-3

Three-dimensional numerical simulation of soft/hard composite-coated textured tools in dry turning of AISI 1045 steel

Yun-Song Lian, Chen-Liang Mu, Ming Liu, Hui-Feng Chen, Bin Yao

2019, 7(2):  133-141.  doi:10.1007/s40436-019-00249-2

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A structural model of a soft/hard compositecoated textured (SHCCT) tool was proposed and substantiated by a three-dimensional numerical simulation. Its dry turning performance as applied to AISI-1045 steel was analyzed via three-factor five-level orthogonal experiments for different coating parameters, including coating thickness, coating material, and thickness ratio of the soft and hard coatings. In addition, the cutting performance of the proposed SHCCT tool was compared with those of uncoated non-textured, coated non-textured, and uncoated textured tools, and its superiority was proved by the significant reductions in the cutting force, and specifically, the cutting temperature. The optimal results were provided by the SHCCT tool with a WS₂/ZrN soft/hard composite coating, a 0.9:0.1 thickness ratio of the above ingredients, and a total coating thickness of 0.5 μm.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00249-2

Multi-response optimization of Ti-6Al-4V turning operations using Taguchi-based grey relational analysis coupled with kernel principal component analysis

Ning Li, Yong-Jie Chen, Dong-Dong Kong

2019, 7(2):  142-154.  doi:10.1007/s40436-019-00251-8

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Ti-6Al-4V has a wide range of applications, especially in the aerospace field; however, it is a difficultto-cut material. In order to achieve sustainable machining of Ti-6Al-4V, multiple objectives considering not only economic and technical requirements but also the environmental requirement need to be optimized simultaneously. In this work, the optimization design of process parameters such as type of inserts, feed rate, and depth of cut for Ti-6Al-4V turning under dry condition was investigated experimentally. The major performance indexes chosen to evaluate this sustainable process were radial thrust, cutting power, and coefficient of friction at the toolchip interface. Considering the nonlinearity between the various objectives, grey relational analysis (GRA) was first performed to transform these indexes into the corresponding grey relational coefficients, and then kernel principal component analysis (KPCA) was applied to extract the kernel principal components and determine the corresponding weights which showed their relative importance. Eventually, kernel grey relational grade (KGRG) was proposed as the optimization criterion to identify the optimal combination of process parameters. The results of the range analysis show that the depth of cut has the most significant effect, followed by the feed rate and type of inserts. Confirmation tests clearly show that the modified method combining GRA with KPCA outperforms the traditional GRA method with equal weights and the hybrid method based on GRA and PCA.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00251-8

A comprehensive review of extrusion-based additive manufacturing processes for rapid production of metallic and ceramic parts

Kedarnath Rane, Matteo Strano

2019, 7(2):  155-173.  doi:10.1007/s40436-019-00253-6

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The extrusion-based additive manufacturing (EAM) technique is recently being employed for rapid production of metals and ceramic components. This technique involves extruding the metal or ceramic material in solid powder form mixed with a binder (i.e., an expendable viscous fluid), which is removed from the part after 3D printing. These technologies rely on the large design freedom allowed and the cost efficiency advantage over alternative metal additive manufacturing processes that are based on high energy beams, such as laser or electron beams. The EAM of metals and ceramics is not yet widespread, but published scientific and technical literature on it is rapidly growing. However, this literature is still less extensive than that on the fused deposition modeling (FDM) of plastics or the selective laser melting (SLM) of metals. This paper aims at filling this gap. FDM and powder injection molding are identified as preceding or enabling technologies for EAM. This paper systematically reviews all aspects of the feedstock EAM processes used for production of complex-shaped parts. The unique characteristics and advantages of these processes are also discussed with respect to materials and process steps. In addition, the key process parameters are explained to illustrate the suitability of the EAM process for diverse application domains.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00253-6

Machine auscultation: enabling machine diagnostics using convolutional neural networks and large-scale machine audio data

Ruo-Yu Yang, Rahul Rai

2019, 7(2):  174-187.  doi:10.1007/s40436-019-00254-5

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Acoustic signals play an essential role in machine state monitoring. Efficient processing of real-time machine acoustic signals improves production quality. However, generating semantically useful information from sound signals is an ill-defined problem that exhibits a highly non-linear relationship between sound and subjective perceptions. This paper outlines two neural network models to analyze and classify acoustic signals emanating from machines:(i) a backpropagation neural network (BPNN); and (ii) a convolutional neural network (CNN). Microphones are used to collect acoustic data for training models from a computer numeric control (CNC) lathe. Numerical experiments demonstrate that CNN performs better than the BP-NN.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00254-5

Time-variant reliability analysis of a continuous system with strength deterioration based on subset simulation

Xi-Nong En, Yi-Min Zhang, Xian-Zhen Huang

2019, 7(2):  188-198.  doi:10.1007/s40436-019-00252-7

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To conduct a reliability analysis for mechanical components, it is necessary to consider the combined influence of strength deterioration and dynamic loads. An efficient method based on subset simulation is proposed in this paper to analyze time-variant reliability by considering the strength deterioration of mechanical components in a continuous system. A gamma process is used to describe the deterioration of system strength. A model for timevariant reliability considering strength deterioration is constructed for a continuous system. A representative example and tubular cantilever structure are assessed to demonstrate the efficiency and accuracy of the proposed method. The reliability probability examples were analyzed using a first-order reliability method and benchmark results for the proposed method were derived using direct Monte Carlo simulation (MCS). The results of the proposed method and MCS are consistent, indicating that the proposed method is an effective reliability analysis method for evaluating small failure probabilities in a continuous system subjected to strength deterioration and dynamic loads.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00252-7

Flow correction control with electromagnetically induced preform resting process

Mohsen Poorzeinolabedin, Kemal Levend Parnas

2019, 7(2):  199-208.  doi:10.1007/s40436-019-00257-2

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Resin flow correction control with electromagnetic field source, a new variation of the vacuum-assisted resin transfer molding (VARTM) process called electromagnetically induced preform resting (EIPR) for dynamical resin flow controlling is introduced to manipulate the flow front and local permeability to prevent the formation of dry spots. This paper proposes an active and real-time flow control approach that is implemented during the composite laminate infusion. The EIPR process applies an electromagnetic field source to pinch (raise) and vibrate the upper flexible mold to rest the fiber preform and increase the local permeability. Vibration action delivers the fluid through the preform. The EIPR process includes a new and creative upper flexible vacuum bag with embedded elements to lift and create local vibrations via an automated gantry system. The control methodology is performed by tracking the flow front with a real-time correction. System capability is demonstrated with three configurations of preform of different preform permeabilities in each experiment. A low permeability preform is employed in these configurations to disturb the flow pattern and cause an artificial problem or pseudo problem during the filling process. The results indicate that this system fills the mold completely and reduces the filling time without any dry spots and therefore creates no waste material.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00257-2

Influence of die geometry on self-piercing riveting of aluminum alloy AA6061-T6 to mild steel SPFC340 sheets

Jiang-Hua Deng, Feng Lyu, Ru-Ming Chen, Zhi-Song Fan

2019, 7(2):  209-220.  doi:10.1007/s40436-019-00250-9

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The self-piercing riveting (SPR) process was used to join 2.0-mm-thick aluminum alloy 6061-T6 and 1.2-mm-thick mild steel SPFC340 sheets. SPR joints produced with a conventional flat-bottom die and conicalsection dies were investigated both experimentally and numerically. Lap shear tests were conducted under quasistatic conditions to evaluate the load-carrying capability of these SPR joints. The effect of variation in die geometry (such as variation in the die groove shape, cone height, and die radius) on the main mechanical response of the joints, namely the peak load and energy absorption, was discussed. The results showed that SPR joints produced with the conical-section dies exhibited a failure mode similar to those produced with a conventional die. All the joints failed by tearing of the top steel sheet. Cracks that occurred in the bottom aluminum alloy 6061-T6 sheet around the rivet leg were a result of tangential tensile stress. The cone height of a conical-section die is the most important parameter affecting the surface quality of Al/steel SPR joints. Conical-section dies with a moderate convex can ensure a good surface quality during the SPR process. In addition, SPR joints with single conical-section die allow higher tensile strength and energy absorption compared to those with double conical-section die.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00250-9

Effects of boron content on environmental embrittlement of ordered Ni₃Fe alloys

Tao Chen, Ye-Xin Chen, Biao Yang, Teng Wang

2019, 7(2):  221-227.  doi:10.1007/s40436-019-00255-4

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The effects of boron content (C_B=0-0.14% (mass fraction)) on the tensile properties and environmental embrittlement of ordered Ni-24%Fe (atom fraction)-B (Ni₃Fe-B) alloys have been investigated using tensile tests in vacuum and under gaseous hydrogen. The results indicate that, when C_B< 0.06% (mass fraction), the tensile strength and elongation of the alloys in vacuum and gaseous hydrogen increase as C_B in the ordered Ni₃Fe-B alloy increases. The tensile strength and elongation are maximum, and the hydrogen embrittlement factor (I_H) is minimum for the ordered Ni₃Fe-0.06%B (mass fraction) alloy. Compared with the ordered B-free Ni₃Fe alloy, I_H of the ordered Ni₃Fe-0.06%B (mass fraction) alloy decreases by 98.1%, and the fracture morphology of the alloy changes from fully intergranular to fully transgranular, when tested in gaseous hydrogen. A critical level of boron segregation at the grain boundaries of ordered Ni₃Fe-B alloys is observed. The hydrogen embrittlement of ordered Ni₃FeB alloys in gaseous hydrogen can be completely suppressed by boron atoms when C_B ≥ 0.06% (mass fraction).

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00255-4

Mechanism of brittle fracture in diamond turning of microlens array on polymethyl methacrylate

Tian-Feng Zhou, Ben-Shuai Ruan, Jia Zhou, Xiao-Bin Dong, Zhi-Qiang Liang, Xi-Bin Wang

2019, 7(2):  228-237.  doi:10.1007/s40436-019-00260-7

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Diamond cutting is a popular method to fabricate microlens array (MLA) on polymethyl methacrylate (PMMA); however, it is limited by brittle fracture, which is formed easily on the surface of MLA during the cutting process. In this paper, the formation mechanism of the brittle fracture is studied via a series of experiments including the slow tool servo (STS) cutting experiment of MLA, surface scratching experiment and sudden-stop cutting experiment. The effects of undeformed chip thickness, feed rate, and machining track on brittle fracture formation are investigated in detail. In addition, based on the fracture formation mechanism, a bi-directional cutting approach is proposed to eliminate the regional brittle fracture of the microlens during diamond cutting. An experiment was then conducted to verify the method; the results demonstrated that bi-directional cutting could eliminate brittle fracture entirely. Finally, a spherical MLA with the form error (v_PV) of 60 nm and the surface roughness (R_a) of 8 nm was successfully fabricated.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00260-7

A strategy to control microstructures of a Ni-based superalloy during hot forging based on particle swarm optimization algorithm

Dong-Dong Chen, Yong-Cheng Lin, Xiao-Min Chen

2019, 7(2):  238-247.  doi:10.1007/s40436-019-00259-0

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In this study, a strategy based on the particle swarm optimization (PSO) algorithm is developed to control the microstructures of a Ni-based superalloy during hot forging. This strategy is composed of three parts, namely, material models, optimality criterions, and a PSO algorithm. The material models are utilized to predict microstructure information, such as recrystallization volume fraction and average grain size. The optimality criterion can be determined by the designed target microstructures and random errors. The developed strategy is resolved using the PSO algorithm, which is an intelligent optimal algorithm. This algorithm does not need a derivable objective function, which renders it suitable for dealing with the complex hot forging process of alloy components. The optimal processing parameters (deformation temperature and strain rate) are obtained by the developed strategy and validated by the hot forging experiments. Uniform and fine target microstructures can be obtained using the optimized processing parameters, which indicates that the developed strategy is effective for controlling the microstructural evolution during the hot forging of the studied superalloy.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00259-0

Structural, ferromagnetic, and optical properties of Fe and Al co-doped ZnO diluted magnetic semiconductor nanoparticles synthesized under high magnetic field

Muhammad Tariq, Ying Li, Wen-Xian Li, Zhong-Rui Yu, Jia-Mei Li, Ye-Min Hu, Ming-Yuan Zhu, Hong-Ming Jin, Yang Liu, Yi-Bing Li, Katerina Skotnicova

2019, 7(2):  248-255.  doi:10.1007/s40436-019-00258-1

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In this study, 2% Fe and 3% Al co-doped ZnO nanoparticles were synthesized using a hydrothermal method under high magnetic field (HMF). The influences of HMF on the structural, optical, and ferromagnetic properties of Fe and Al co-doped ZnO nanoparticles were characterized and analyzed. The single-phase wurtzite structure of the synthesized samples was confirmed using X-ray diffraction (XRD), high-resolution transmission electron microscopy (HRTEM), and Raman spectroscopy analysis. The application of HMF decreases the particle size of the spherical nanocrystal as observed by scanning electron microscopy (SEM). Optical analysis indicated that the absorption edge shifted towards a higher wavelength (red shift). The nanoparticles synthesized under the HMF exhibited high room temperature ferromagnetism (RTFM) performance because of the high oxygen vacancy (VO) content as revealed by X-ray photoelectron spectroscopy (XPS), which was in agreement with the prediction of the bound magnetic polarons theory.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00258-1