Journal Description
Journal of Manufacturing and Materials Processing
Journal of Manufacturing and Materials Processing
is an international, peer-reviewed, open access journal on the scientific fundamentals and engineering methodologies of manufacturing and materials processing published bimonthly online by MDPI.
- Open Access— free for readers, with article processing charges (APC) paid by authors or their institutions.
- High Visibility: indexed within Scopus, ESCI (Web of Science), Inspec, CAPlus / SciFinder, Ei Compendex and other databases.
- Journal Rank: JCR - Q1 (Engineering, Mechanical) / CiteScore - Q2 (Mechanical Engineering)
- Rapid Publication: manuscripts are peer-reviewed and a first decision is provided to authors approximately 14.7 days after submission; acceptance to publication is undertaken in 2.8 days (median values for papers published in this journal in the first half of 2024).
- Recognition of Reviewers: reviewers who provide timely, thorough peer-review reports receive vouchers entitling them to a discount on the APC of their next publication in any MDPI journal, in appreciation of the work done.
Impact Factor:
3.3 (2023);
5-Year Impact Factor:
3.3 (2023)
Latest Articles
Innovative Structural Optimization and Dynamic Performance Enhancement of High-Precision Five-Axis Machine Tools
J. Manuf. Mater. Process. 2024, 8(4), 181; https://doi.org/10.3390/jmmp8040181 - 19 Aug 2024
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To satisfy the requirements of five-axis processing quality, this article improves and optimizes the machine tool structure design to produce improved dynamic characteristics. This study focuses on the investigation of five-axis machine tools’ static and dynamic stiffness as well as structural integrity. We
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To satisfy the requirements of five-axis processing quality, this article improves and optimizes the machine tool structure design to produce improved dynamic characteristics. This study focuses on the investigation of five-axis machine tools’ static and dynamic stiffness as well as structural integrity. We also include performance optimization and experimental verification. We use the finite element approach as a structural analysis tool to evaluate and compare the individual parts of the machine created in this study, primarily the saddle, slide table, column, spindle head, and worktable. We discuss the precision of the machine tool model and relative space distortion at each location. To meet the requirements of the actual machine, we optimize the structure of the five-axis machine tool based on the parameters and boundary conditions of each component. The machine’s weight was 15% less than in the original design model, the material it was subjected to was not strained, and the area of the structure where the force was considerably deformed was strengthened. We evaluate the AM machine’s impact resistance to compare the vibrational deformation observed in real time with the analytical findings. During modal analysis, all the order of frequencies were determined to be 97.5, 110.4, 115.6, and 129.6 Hz. The modal test yielded the following orders of frequencies: 104, 118, 125, and 133 Hz. Based on the analytical results, the top three order error percentages are +6.6%, +6.8%, +8.1%, and +2.6%. In ME’scope, the findings of the modal test were compared with the modal assurance criteria (MAC) analysis. According to the static stiffness analysis’s findings, the main shaft and screw have quite substantial major deformations, with a maximum deformation of 33.2 µm. Force flow explore provides the relative deformation amount of 26.98 µm from the rotating base (C) to the tool base, when a force of 1000 N is applied in the X-axis direction, which is more than other relative deformation amounts. We also performed cutting transient analysis, cutting spectrum analysis, steady-state thermal analysis, and analysis of different locations of the machine tool. All of these improvements may effectively increase the stiffness of the machine structure as well improve the machine’s dynamic characteristics and increases its machining accuracy. The topology optimization method checks how the saddle affects the machine’s stability and accuracy. This research will boost smart manufacturing in the machine tool sector, leading to notable advantages and technical innovations.
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Open AccessArticle
Formability Assessment of Additively Manufactured Materials via Dieless Nakajima Testing
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Rui F. V. Sampaio, Pedro M. S. Rosado, João P. M. Pragana, Ivo M. F. Bragança, Carlos M. A. Silva, Luís G. Rosa and Paulo A. F. Martins
J. Manuf. Mater. Process. 2024, 8(4), 180; https://doi.org/10.3390/jmmp8040180 - 18 Aug 2024
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This paper delves into the formability of material deposited by wire arc additive manufacturing. It presents a novel dieless Nakajima testing procedure that offers a practical solution for obtaining strain loading paths up to failure directly from the deposited material without the need
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This paper delves into the formability of material deposited by wire arc additive manufacturing. It presents a novel dieless Nakajima testing procedure that offers a practical solution for obtaining strain loading paths up to failure directly from the deposited material without the need for extracting sheet blanks. The procedure involved machining a region of the deposited material to the desired shape and thickness and using a press to drive and control the movement of a hemispherical punch. The test was designed using finite element modeling, and its effectiveness in obtaining the required strain loading paths directly from the deposited material was verified through experimentation with digital image correlation. Importantly, this novel test eliminates the need for the special-purpose tool setup required in conventional Nakajima sheet formability tests, thereby simplifying the overall testing process.
Full article
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Open AccessArticle
Production of Aluminium-Polymer Joints by Friction Stir Spot Welding
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Miguel A. R. Pereira, Ivan Galvão, José D. M. Costa, Ana M. Amaro and Rui M. Leal
J. Manuf. Mater. Process. 2024, 8(4), 179; https://doi.org/10.3390/jmmp8040179 - 17 Aug 2024
Abstract
The joining of AA6082-T6 and polyamide 6 using pinless friction stir spot welding was investigated in this study. The influence of the clamping frame geometry was studied and the welds produced were characterized based on their morphology and mechanical performance. The morphological analysis
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The joining of AA6082-T6 and polyamide 6 using pinless friction stir spot welding was investigated in this study. The influence of the clamping frame geometry was studied and the welds produced were characterized based on their morphology and mechanical performance. The morphological analysis was evaluated based on the comparison of the different joining areas and on the presence of defects in the resolidified layer of the polymer. In turn, the mechanical performance of the joints was evaluated by tensile-shear testing. Additionally, the influence of plunge depth parameter was studied for the clamping frame geometry providing the best mechanical performance. While the clamping frame geometry had a greater impact on the size of the joining areas, therefore influencing the micro-mechanical interlocking mechanisms, the plunge depth mainly affected the plunging of the aluminium into the polymeric material, therefore affecting the macro-mechanical interlocking mechanism. The strongest joints, which failed for a load of about 2700 N, were produced with the clamping frame geometry that restricted the welding zone the least, and used the highest plunge depth.
Full article
(This article belongs to the Special Issue Joining of Unweldable Materials: Concepts, Techniques and Processes)
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Open AccessArticle
Extension of a Contact Subroutine for Composite Ring Rolling to Include Temperature Dependency
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Laurenz Kluge, Stefan Stergianou, Moritz Gouverneur and David Bailly
J. Manuf. Mater. Process. 2024, 8(4), 178; https://doi.org/10.3390/jmmp8040178 - 16 Aug 2024
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By combining the ring rolling and roll bonding processes, the product spectrum can be additionally expanded. Since a successful composite ring rolling process requires a higher growth tendency for the inner ring, previous publications commonly included a softer inner ring to reduce the
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By combining the ring rolling and roll bonding processes, the product spectrum can be additionally expanded. Since a successful composite ring rolling process requires a higher growth tendency for the inner ring, previous publications commonly included a softer inner ring to reduce the flow resistance of the inner ring or specific geometries for rings and tools. In this work, the material combination of a 100Cr6 (DIN 1.3505, AISI 52100) outer ring and a 42CrMo4 (DIN 1.7225, AISI 4140) inner ring is used to show that the composite ring rolling process is also possible for material combinations with a balanced flow stress ratio and equal wall thicknesses. In earlier publications, the influence of temperature was neglected. As the influence on the yield stress and thus on the success of the process has a significant influence, this should be considered in order to be able to make a reliable statement. For this purpose, the bond formation of the two materials was investigated by bonding experiments, and an existing bond formation model was extended with respect to the temperature dependency. On the basis of this model, the process control parameters were investigated using FE simulations, and a ring rolling experiment was carried out.
Full article
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Open AccessArticle
Additive Friction Stir Deposition of a Tantalum–Tungsten Refractory Alloy
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R. Joey Griffiths, Alexander E. Wilson-Heid, Marissa A. Linne, Eleanna V. Garza, Arnold Wright and Aiden A. Martin
J. Manuf. Mater. Process. 2024, 8(4), 177; https://doi.org/10.3390/jmmp8040177 - 14 Aug 2024
Abstract
Additive friction stir deposition (AFSD) is a solid-state metal additive manufacturing technique, which utilizes frictional heating and plastic deformation to create large deposits and parts. Much like its cousin processes, friction stir welding and friction stir processing, AFSD has seen the most compatibility
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Additive friction stir deposition (AFSD) is a solid-state metal additive manufacturing technique, which utilizes frictional heating and plastic deformation to create large deposits and parts. Much like its cousin processes, friction stir welding and friction stir processing, AFSD has seen the most compatibility and use with lower-temperature metals, such as aluminum; however, there is growing interest in higher-temperature materials, such as titanium and steel alloys. In this work, we explore the deposition of an ultrahigh-temperature refractory material, specifically, a tantalum–tungsten (TaW) alloy. The solid-state nature of AFSD means refractory process temperatures are significantly lower than those for melt-based additive manufacturing techniques; however, they still pose difficult challenges, especially in regards to AFSD tooling. In this study, we perform initial deposition trials of TaW using twin-rod-style AFSD with a high-temperature tungsten–rhenium-based tool. Many challenges arise because of the high temperatures of the process and high mechanical demand on AFSD machine hardware to process the strong refractory alloy. Despite these challenges, successful deposits of the material were produced and characterized. Mechanical testing of the deposited material shows improved yield strength over that of the annealed reference material, and this strengthening is mostly attributed to the refined recrystallized microstructure typical of AFSD. These findings highlight the opportunities and challenges associated with ultrahigh-temperature AFSD, as well as provide some of the first published insights into twin-rod-style AFSD process behaviors.
Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing and Material Characterization Techniques)
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Open AccessArticle
Laser Powder Bed Fusion of Superelastic Ti-Ni Lattice Structures: Process Design and Testing
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Anatolie Timercan, Donatien Campion, Patrick Terriault and Vladimir Brailovski
J. Manuf. Mater. Process. 2024, 8(4), 176; https://doi.org/10.3390/jmmp8040176 - 13 Aug 2024
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Laser powder bed fusion allows the production of complex geometries and eases the shaping of difficult-to-transform materials, such as near-equiatomic Ti-Ni shape memory alloys. In this study, a numerical model was used to select 11 sets of printing parameters with different volumetric energy
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Laser powder bed fusion allows the production of complex geometries and eases the shaping of difficult-to-transform materials, such as near-equiatomic Ti-Ni shape memory alloys. In this study, a numerical model was used to select 11 sets of printing parameters with different volumetric energy densities (VEDs) and build rates (BRs) to produce bulk Ti-50.26at%Ni alloy specimens. The manufactured specimens were studied in terms of their structural integrity, printed density, chemical composition, transformation temperatures, and crystalline phases. At high VEDs and low BRs, a significant decrease in the nickel content was observed. VED = 90 J/mm3 and BR = 10 cm3/h yielded a printed density of 99.94% and an austenite finish temperature of Af = 26.3 °C. The same printing conditions were used to produce 60% porous diamond and gyroid lattice structures. After heat treatment at 500 °C for 30 min, the diamond lattices manifested larger apparent recovery strains (7 vs. 6%), higher compliance (2.9 vs. 3.4 GPa), and similar yield stresses (~48 MPa) compared to their gyroid equivalents. The numerical model predicted that at an equivalent apparent compression strain of 6%, only a ~2% volume fraction of the diamond lattice material underwent plastic deformation as compared to ~20% for its gyroid equivalent.
Full article
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Open AccessArticle
Real-Time Simulation of Tube Hydroforming by Integrating Finite-Element Method and Machine Learning
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Liang Cheng, Haijing Guo, Lingyan Sun, Chao Yang, Feng Sun and Jinshan Li
J. Manuf. Mater. Process. 2024, 8(4), 175; https://doi.org/10.3390/jmmp8040175 - 12 Aug 2024
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The real-time, full-field simulation of the tube hydroforming process is crucial for deformation monitoring and the timely prediction of defects. However, this is rather difficult for finite-element simulation due to its time-consuming nature. To overcome this drawback, in this paper, a surrogate model
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The real-time, full-field simulation of the tube hydroforming process is crucial for deformation monitoring and the timely prediction of defects. However, this is rather difficult for finite-element simulation due to its time-consuming nature. To overcome this drawback, in this paper, a surrogate model framework was proposed by integrating the finite-element method (FEM) and machine learning (ML), in which the basic methodology involved interrupting the computational workflow of the FEM and reassembling it with ML. Specifically, the displacement field, as the primary unknown quantity to be solved using the FEM, was mapped onto the displacement boundary conditions of the tube component with ML. To this end, the titanium tube material as well as the hydroforming process was investigated, and a fairly accurate FEM model was developed based on the CPB06 yield criterion coupled with a simplified Kim–Tuan hardening model. Numerous FEM simulations were performed by varying the loading conditions to generate the training database for ML. Then, a random forest algorithm was applied and trained to develop the surrogate model, in which the grid search method was employed to obtain the optimal combination of the hyperparameters. Sequentially, the principal strain, the effective strain/stress, as well as the wall thickness was derived according to continuum mechanics theories. Although further improvements were required in certain aspects, the developed FEM-ML surrogate model delivered extraordinary accuracy and instantaneity in reproducing multi-physical fields, especially the displacement field and wall-thickness distribution, manifesting its feasibility in the real-time, full-field simulation and monitoring of deformation states.
Full article
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Open AccessArticle
Fundamental Investigation of the Application Behavior and Stabilization Potential of Milling Tools with Structured Flank Faces on the Minor Cutting Edges
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Raphael Isaak Elias Schönecker, Jonas Baumann, Rafael Garcia Carballo and Dirk Biermann
J. Manuf. Mater. Process. 2024, 8(4), 174; https://doi.org/10.3390/jmmp8040174 - 10 Aug 2024
Abstract
In milling processes in which material removal is performed periodically from solid material, dynamic effects are generally considered to be responsible for instabilities and subsequent productivity limits. Usually, in such applications, the process-inherent complex dynamic load spectrum on machines, tools and workpieces is
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In milling processes in which material removal is performed periodically from solid material, dynamic effects are generally considered to be responsible for instabilities and subsequent productivity limits. Usually, in such applications, the process-inherent complex dynamic load spectrum on machines, tools and workpieces is considered together with vibration-based relative displacements that can be attributed to the regenerative effect. There are numerous techniques in the literature addressing the suppression of these dynamic effects, but they require a large amount of analysis and implementation effort as well as specific expert knowledge. The approach presented here, however, provides a universally applicable method for suppressing chatter vibrations and deflections. By applying structure elements to the flanks of the minor cutting edges of HSS end mills, it was possible to increase the chatter-free limiting depth of cut ap,crit in the milling processes of the aluminum alloy EN AW-7075. Structured tools were used in ramp milling tests to investigate various effects, such as the influence of certain geometric design features on the stabilization potential compared to a reference tool. Furthermore, the effects of varied process parameter configurations and wear-related effects on the performance of the tool concept were focused on as well. The three key design features of the cutting edge and the structured profiles were identified from the results of the investigation, which, when combined in the most efficient design, in each case led to the development of an optimized structure and process configuration with cumulative potential for increasing the stability limit up to 200%.
Full article
(This article belongs to the Special Issue Dynamics and Machining Stability for Flexible Systems)
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Open AccessArticle
Real-Time Milling Chatter Detection and Control with Axis Encoder Feedback and Spindle Speed Manipulation
by
Hakan Çalışkan
J. Manuf. Mater. Process. 2024, 8(4), 173; https://doi.org/10.3390/jmmp8040173 - 10 Aug 2024
Abstract
This paper introduces a complete real-time algorithm, where the chatter is detected and eliminated by spindle speed manipulation via the chatter energy feedback calculated from the axis encoder measurement. The proposed method does not require profound knowledge of the machining dynamics; instead, the
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This paper introduces a complete real-time algorithm, where the chatter is detected and eliminated by spindle speed manipulation via the chatter energy feedback calculated from the axis encoder measurement. The proposed method does not require profound knowledge of the machining dynamics; instead, the entire algorithm exploits the fact that milling vibrations consist of forced vibrations at spindle speed harmonics and chatter vibrations that are close to one of the natural modes, with sidebands which are spread at the multiples of spindle speed frequency above and below the chatter frequency. The developed algorithm is able to identify the amplitude, phase and frequency of all the harmonics constituting the periodic forced and chatter vibrations. The key challenge is to select dominant chatter frequencies for the calculation of a robust and accurate chatter energy ratio feedback; this is achieved by utilizing the frequency estimation variance of EKF as a novel chatter indicator. Based on the chatter energy ratio feedback, the controller overrides the spindle speed in order to suppress the chatter energy below a particular threshold value. The varying spindle speed challenge is handled by updating the state transition matrices of the Kalman filters and real-time calculation of the band-pass filter coefficients, based on the derived discrete time transfer functions. The developed algorithm is tested on a Deckel FP5cc CNC which is in-house retrofitted and has a PC-based controller for the real-time application of the proposed algorithm. It is shown that the real-time chatter frequency and amplitude estimates are compatible with off-line FFT analysis, and chatter can be successfully eliminated by energy feedback.
Full article
(This article belongs to the Special Issue Dynamics and Machining Stability for Flexible Systems)
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Open AccessArticle
Efficiency and Microstructural Forecasts in Friction Stir Extrusion Compared to Traditional Hot Extrusion of AA6061
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Sara Bocchi, Marco Zambelli, Gianluca D’Urso and Claudio Giardini
J. Manuf. Mater. Process. 2024, 8(4), 172; https://doi.org/10.3390/jmmp8040172 - 9 Aug 2024
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Conventional aluminum recycling consumes a substantial amount of energy and has a negative impact on secondary alloys. To address this challenging topic, Friction Stir Extrusion has been patented, which represents an innovative solid-state recycling technique that enables the direct extrusion of components from
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Conventional aluminum recycling consumes a substantial amount of energy and has a negative impact on secondary alloys. To address this challenging topic, Friction Stir Extrusion has been patented, which represents an innovative solid-state recycling technique that enables the direct extrusion of components from recyclable materials. In recent years, developing simulation models for Friction Stir Extrusion has become essential for gaining a deeper understanding of its underlying physics. Simultaneously, control of the microstructure evolution of extruded profiles is required, as it has a considerable influence on mechanical properties. This research involves a single Lagrangian model, adapted for both the FSE and the traditional hot extrusion processes. The simulations explored various rotational speeds and feed rates, revealing significant effects on grain size and bonding quality. To this model were applied different sub-routines, to investigate the impact of the FSE process with respect to the traditional hot extrusion process in terms of energy demands, quality and microstructure of the extruded pieces. The findings demonstrated that optimal grain refinement occurs at intermediate rotational speeds (600–800 rpm) combined with lower feed rates (1 mm/s). The energy analyses indicated that FSE requires lower total energy compared to traditional hot extrusion, primarily due to the reduced axial thrust and more efficient thermal management. As a result, it was possible to ensure the ability of the developed simulative model to be fully adapted for both processes and to forecast the microstructural changes directly during the process and not only at the end of the extrusion. The study concludes that FSE is a highly efficient method for producing high-quality extruded rods, with the developed simulation model providing valuable insights for process optimization. The model’s adaptability to various starting materials and conditions highlights its potential for broader applications in extrusion technology.
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Open AccessArticle
Explainable AI Techniques for Comprehensive Analysis of the Relationship between Process Parameters and Material Properties in FDM-Based 3D-Printed Biocomposites
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Namrata Kharate, Prashant Anerao, Atul Kulkarni and Masuk Abdullah
J. Manuf. Mater. Process. 2024, 8(4), 171; https://doi.org/10.3390/jmmp8040171 - 6 Aug 2024
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This study investigates the complex relationships between process parameters and material properties in FDM-based 3D-printed biocomposites using explainable AI techniques. We examine the effects of key parameters, including biochar content (BC), layer thickness (LT), raster angle (RA), infill pattern (IP), and infill density
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This study investigates the complex relationships between process parameters and material properties in FDM-based 3D-printed biocomposites using explainable AI techniques. We examine the effects of key parameters, including biochar content (BC), layer thickness (LT), raster angle (RA), infill pattern (IP), and infill density (ID), on the tensile, flexural, and impact strengths of FDM-printed pure PLA and biochar-reinforced PLA composites. Mechanical testing was used to measure the ultimate tensile strength (UTS), flexural strength (FS), and impact strength (IS) of the 3D-printed samples. The extreme gradient boosting (XGB) algorithm was used to build a predictive model based on the data collected from mechanical testing. Shapley Additive Explanations (SHAP), Local Interpretable Model-Agnostic Explanations (LIME), and Partial Dependence Plot (PDP) techniques were implemented to understand the effects of the interactions of key parameters on mechanical properties such as UTS, FS, and IS. Prediction by XGB was accurate for UTS, FS, and IS, with R-squared values of 0.96, 0.95, and 0.85, respectively. The explanation showed that infill density has the most significant influence on UTS and FS, with SHAP values of +2.75 and +5.8, respectively. BC has the most significant influence on IS, with a SHAP value of +2.69. PDP reveals that using 0.3 mm LT and 30° RA enhances mechanical properties. This study contributes to the field of the application of artificial intelligence in additive manufacturing. A novel approach is presented in which machine learning and XAI techniques such as SHAP, LIME, and PDP are combined and used not only for optimization but also to provide valuable insights about the interaction of the process parameters with mechanical properties.
Full article
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Open AccessArticle
Tool Concept for a Solid Carbide End Mill for Roughing and Finishing of the Tool Steel Toolox 44
by
Steffen Globisch, Markus Friedrich, Nils Heidemann and Frank Döpper
J. Manuf. Mater. Process. 2024, 8(4), 170; https://doi.org/10.3390/jmmp8040170 - 6 Aug 2024
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In tool and mold making, components are typically first pre-machined in a soft state with residual stock allowance, as economical production is not possible in a hardened state due to the enormous tool wear. This extends the process chain and therefore also the
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In tool and mold making, components are typically first pre-machined in a soft state with residual stock allowance, as economical production is not possible in a hardened state due to the enormous tool wear. This extends the process chain and therefore also the throughput times. This paper presents an innovative tool concept for a solid carbide end mill in order to be able to carry out roughing and finishing in a hardened state. First, the structure of the innovative solid carbide end mill is described. Afterwards, the results of experimental tests are presented and discussed. These describe the suitability of the tool concept and include further investigations that examine the influence of the helix angle on the process behavior during the machining of the tool steel Toolox 44. To evaluate the process behavior, the development of process forces, chip formation, tool wear and component quality over the tool life are analyzed.
Full article
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Open AccessArticle
Tool Path Strategies for Efficient Milling of Thin-Wall Features
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Lutfi Taner Tunc and Deniz Arda Gulmez
J. Manuf. Mater. Process. 2024, 8(4), 169; https://doi.org/10.3390/jmmp8040169 - 5 Aug 2024
Abstract
The milling of thin-wall geometries has been a challenge due to inherent chatter vibrations and workpiece deflections. Moreover, tool path generation strategies in CAD-CAM systems are not able to fully address all such concerns. The objective of this study is to demonstrate potential
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The milling of thin-wall geometries has been a challenge due to inherent chatter vibrations and workpiece deflections. Moreover, tool path generation strategies in CAD-CAM systems are not able to fully address all such concerns. The objective of this study is to demonstrate potential 5-axis milling tool path strategies, which do not exist in the conventional tool path generation. The demonstration is performed for increased efficiency in milling of thin-wall features considering the main limitation of chatter. The effects of varying workpiece dynamics on milling stability are shown in case studies through simulations and cutting experiments. Based on the simulation results, tool path strategies are developed. The effect of tool path generation and the relation to parameter selection are highlighted. Most of the discussion relies on previously reported experimental results. The results showed that by tailoring the tool path considering the concerns and limitations associated with thin-wall part structure and geometry, it is possible to increase productivity by at least two folds.
Full article
(This article belongs to the Special Issue Dynamics and Machining Stability for Flexible Systems)
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Open AccessArticle
Revealing the Relationship between Critical Inlet Velocity and a Double-Layer Oxide Film Combined with Low-Pressure Casting Technology
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Ziao Qiu, Chaojun Zhang, Lunyong Zhang, Fuyang Cao, Hongxian Shen, Zhishuai Jin, Guanyu Cao, Xinyi Zhao, Heqian Song and Jianfei Sun
J. Manuf. Mater. Process. 2024, 8(4), 168; https://doi.org/10.3390/jmmp8040168 - 3 Aug 2024
Abstract
In the context of low-pressure casting, an excessive inlet velocity may result in the introduction of an oxide film and air into a liquid metal, leading to the formation of a two-layer film structure within the casting. Such defects can significantly degrade the
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In the context of low-pressure casting, an excessive inlet velocity may result in the introduction of an oxide film and air into a liquid metal, leading to the formation of a two-layer film structure within the casting. Such defects can significantly degrade the mechanical properties of the castings. In order to optimize the advantages of low-pressure casting, an empirically designed equation for the inlet velocity was formulated and the concept of critical inlet velocity was further refined. A comprehensive numerical simulation was conducted to meticulously analyze the liquid metal spreading phase within the cavity. Subsequently, low-pressure casting experiments were carried out with actual castings of an A357 alloy, using two different entrance velocities—one critical and the other exceeding the critical entrance velocity. Tensile test specimens were extracted from the castings for the comparative evaluation of mechanical properties. It was observed that the average tensile strength of specimens cast at the critical inlet velocity exhibited a notable 16% enhancement. In contrast, specimens cast at velocities exceeding the critical inlet velocity manifested the presence of double oxide film defects. This evidence suggests that casting at a velocity faster than the critical inlet velocity leads to the formation of double oxide film defects, which in turn reduces the mechanical properties of the castings.
Full article
(This article belongs to the Special Issue Industry 4.0: Manufacturing and Materials Processing)
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Open AccessArticle
Comparison of Modulation-Assisted Machining Strategies for Achieving Chip Breakage When Turning 17-4 PH Stainless Steel
by
Ainhoa Robles, Asier Astarloa, Iñigo Llanos, Iker Mancisidor, Maria Helena Fernandes and Jokin Munoa
J. Manuf. Mater. Process. 2024, 8(4), 167; https://doi.org/10.3390/jmmp8040167 - 2 Aug 2024
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Chip morphology is an intrinsic characteristic of the machining process that determines the quality of the process. When machining low machinability materials, the chips formed are usually long, continuous, and difficult to break. Due to the negative effect of the accumulation of the
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Chip morphology is an intrinsic characteristic of the machining process that determines the quality of the process. When machining low machinability materials, the chips formed are usually long, continuous, and difficult to break. Due to the negative effect of the accumulation of the chip along the process, chip breakage and the correct extraction out of the machining area have become indispensable requirements. Although numerous chip-breaking methodologies have been proposed, modulation-assisted machining (MAM) is one of the most promising approaches, due to its independence from the workpiece material, tool geometry, and cutting conditions. In this work, a comparison of different modulation-assisted machining strategies, based on the modulation of the feed (F-MAM) or the depth of cut (D-MAM), were experimentally evaluated and compared to conventional turning in terms of chip morphology, surface roughness, and tool wear. Results showed that both MAM strategies enabled chip breakage and improved chip evacuation in comparison to conventional turning; however, D-MAM showed a better performance in terms of tool wear and surface roughness.
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Open AccessArticle
Investigation of Laser Powder Bed Fusion Parameters with Respect to Their Influence on the Thermal Conductivity of 316L Samples
by
Fabian Eichler, Nicolae Balc, Sebastian Bremen and Philipp Nink
J. Manuf. Mater. Process. 2024, 8(4), 166; https://doi.org/10.3390/jmmp8040166 - 2 Aug 2024
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The thermal conductivity of components manufactured using Laser Powder Bed Fusion (LPBF), also called Selective Laser Melting (SLM), plays an important role in their processing. Not only does a reduced thermal conductivity cause residual stresses during the process, but it also makes subsequent
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The thermal conductivity of components manufactured using Laser Powder Bed Fusion (LPBF), also called Selective Laser Melting (SLM), plays an important role in their processing. Not only does a reduced thermal conductivity cause residual stresses during the process, but it also makes subsequent processes such as the welding of LPBF components more difficult. This article uses 316L stainless steel samples to investigate whether and to what extent the thermal conductivity of specimens can be influenced by different LPBF parameters. To this end, samples are set up using different parameters, orientations, and powder conditions and measured by a heat flow meter using stationary analysis. The heat flow meter set-up used in this study achieves good reproducibility and high measurement accuracy, so that comparative measurements between the various LPBF influencing factors to be tested are possible. In summary, the series of measurements show that the residual porosity of the components has the greatest influence on conductivity. The degradation of the powder due to increased recycling also appears to be detectable. The build-up direction shows no detectable effect in the measurement series.
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Open AccessArticle
A Framework for Effective Virtual Commissioning: Guiding Principles for Seamless System Integration
by
Richárd Korpai, Norbert Szántó and Ádám Balázs Csapó
J. Manuf. Mater. Process. 2024, 8(4), 165; https://doi.org/10.3390/jmmp8040165 - 1 Aug 2024
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Virtual commissioning (VC), defined as the simulation and testing of systems in a virtual environment before physical implementation, plays a key role in addressing the challenges of integrating and validating complex systems efficiently and effectively. This paper focuses on the topic of virtual
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Virtual commissioning (VC), defined as the simulation and testing of systems in a virtual environment before physical implementation, plays a key role in addressing the challenges of integrating and validating complex systems efficiently and effectively. This paper focuses on the topic of virtual commissioning, summarizing and organizing existing research in the field. The paper provides a comprehensive overview of various design methods and technologies currently in use. A case study of virtual commissioning is also presented within the area of the Cyber-Physical Manufacturing Systems Laboratory of the Széchenyi István University, detailing the solution steps taken. Drawing on both research and practical experience, the paper proposes a novel framework to support virtual commissioning design, referred to as the “Virtual Commissioning House” (VCH). The methodology is evaluated through comparisons with existing virtual commissioning solutions, demonstrating its effectiveness.
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Open AccessReview
Application of 3D and 4D Printing in Electronics
by
Matilde Aronne, Miriam Polano, Valentina Bertana, Sergio Ferrero, Francesca Frascella, Luciano Scaltrito and Simone Luigi Marasso
J. Manuf. Mater. Process. 2024, 8(4), 164; https://doi.org/10.3390/jmmp8040164 - 31 Jul 2024
Abstract
Nowadays, additive manufacturing technologies have impacted different engineering sectors. Three- and four-dimensional printing techniques are increasingly used in soft and flexible electronics thanks to the possibility of working contemporarily with several materials on various substrates. The materials portfolio is wide, as well as
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Nowadays, additive manufacturing technologies have impacted different engineering sectors. Three- and four-dimensional printing techniques are increasingly used in soft and flexible electronics thanks to the possibility of working contemporarily with several materials on various substrates. The materials portfolio is wide, as well as printing processes. Shape memory polymers, together with composites, have gained great success in the electronic field and are becoming increasingly popular for fabricating pH, temperature, humidity, and stress sensors that are integrated into wearable, stretchable, and flexible devices, as well as for the fabrication of communication devices, such as antennas. Here, we report an overview of the state of the art about the application of 4D printing technologies and smart materials in electronics.
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(This article belongs to the Topic Modern Technologies and Manufacturing Systems, 2nd Volume)
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Open AccessArticle
Experimental and Machine Learning Study on Friction Stir Surface Alloying in Al1050-Cu Alloy
by
Siamak Pedrammehr, Moosa Sajed, Kais I. Abdul-Lateef Al-Abdullah, Sajjad Pakzad, Ahad Zare Jond, Mohammad Reza Chalak Qazani and Mir Mohammad Ettefagh
J. Manuf. Mater. Process. 2024, 8(4), 163; https://doi.org/10.3390/jmmp8040163 - 30 Jul 2024
Abstract
This study employs friction stir processing to create a surface alloy using Al1050 aluminum as the base material, with Cu powder applied to enhance surface properties. Various parameters, including tool rotation speed, feed rate, and the number of passes, are investigated for their
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This study employs friction stir processing to create a surface alloy using Al1050 aluminum as the base material, with Cu powder applied to enhance surface properties. Various parameters, including tool rotation speed, feed rate, and the number of passes, are investigated for their effects on the microstructure and mechanical properties of the resulting surface alloy. The evaluation methods include tensile testing, microhardness measurements, and metallographic examinations. The initial friction stir alloying pass produced a non-uniform stir zone, which was subsequently homogenized with additional passes. Through the plasticization of Al1050, initial agglomerates of copper particles were compacted into larger ones and saturated with aluminum. The alloyed samples exhibited up to an 80% increase in the strength of the base metal. This significant enhancement is attributed to the Cu content and grain size refinement post-alloying. Additionally, machine learning techniques, specifically Genetic Programming, were used to model the relationship between processing parameters and the mechanical properties of the alloy, providing predictive insights for optimizing the surface alloying process.
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(This article belongs to the Special Issue Recent Developments in Friction Stir Welding Technology and Applications)
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Open AccessArticle
Production of Ceramic Investment Casting Shells Using Lithography-Based Ceramic Manufacturing and Binder Jetting Technology
by
Irina Sviridova, Hendrik Holling, Wenchao Tang, Alexander Küll and Christian Mendieta Terán
J. Manuf. Mater. Process. 2024, 8(4), 162; https://doi.org/10.3390/jmmp8040162 - 29 Jul 2024
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This paper presents a comprehensive analysis of the utilization of 3D printing technology for the fabrication of ceramic shells in the context of investment casting. This study encompasses an exploration of various 3D printing techniques such as binder jetting technology and lithography-based ceramic
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This paper presents a comprehensive analysis of the utilization of 3D printing technology for the fabrication of ceramic shells in the context of investment casting. This study encompasses an exploration of various 3D printing techniques such as binder jetting technology and lithography-based ceramic manufacturing applied to ceramic materials tailored for investment casting applications for different materials. Comparative analyses between conventionally manufactured shells and those produced through 3D printing techniques are presented, shedding light on the potential advantages and challenges associated with the adoption of additive manufacturing in investment casting processes. The findings of this study reveal that both methods offer viable solutions for creating ceramic materials suitable as shells for investment casting. Both lithography-based ceramic manufacturing and binder jetting technology exhibit unique advantages and challenges. Lithography-based ceramic manufacturing demonstrates a superior surface finish and resolution, making it particularly suitable for intricate designs and fine details. On the other hand, binder jetting technology presents advantages in terms of speed and scalability, allowing for the rapid production of larger components.
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