Welding monitoring technology based on machine vision has been widely researched in academic and industry, especially in the background of Industry 4.0, in that it can contribute to welding quality and productivity improvement. This paper outlines the technical points of welding status monitoring based on machine vision, including hardware and software. First of all, in the hardware part, the active

The digitization thrust on high-value manufacturing and services opens up new opportunities for ensuring total system uptime, reliability, and efficiency particularly for mission-critical high-value assets. The digitization process evolves intelligent manufacturing systems (IMS) which transforms maintenance into predictive reliability for achieving consistent quality throughout manufacturing process

This paper presents a tolerance-based adaptive slicing (TAS) method to find an optimal trade-off between the manufacturing time and the print quality for the region of mechanical parts with geometric dimensioning and tolerancing (GD&T) requirements. Compared with other traditional adaptive slicing algorithms, the cylindricity and flatness are chosen as the form metric which can improve the part surface

Carbon fiber-toughened silicon carbide composite matrix composite (Cf/SiC composite) occupies an important position in the field of aerospace due to its excellent mechanical properties. Because Cf/SiC composite have good high temperature resistance and hardness, machining traditional Cf/SiC composite is a difficult and time-consuming process. In this paper, two-dimensional braided Cf/SiC composite

Diamond wire sawing has obtained 90% of the single-crystal silicon–based photovoltaic market, mainly for its high production efficiency, high wafer quality, and low tool wear. The diamond wire wear is strongly influenced by the temperatures in the grain-workpiece contact zone; and yet, research studies on experimental investigations and modeling are currently lacking. In this direction, a temperature

Owing to its excellent physical and chemical properties, such as high temperature resistance, corrosion resistance, and low density, optical glass is widely used in high-tech fields such as aviation, aerospace, and national defense; however, the grinding force during the processing of optical glass seriously affects the surface quality. Therefore, in the present paper, a mathematical model of the grinding

The high-speed welding of friction stir welding can improve the production efficiency of the equipment. The orthogonal experiment method was used to study the high-speed welding process parameters of aluminum alloy. The mechanical properties of welded joints were tested, and the influence of process parameters on welding quality was analyzed. A data collection platform was designed, and the spindle

The scientific fields of additive manufacturing and especially the extrusion-based technologies have gained immense attention in numerous commercial and research areas in the past decades. However, monitoring the manufacturing procedure and detecting errors during the process remain a technological challenge in the field. Generally, defect detection and dimensional accuracy inspection of the produced

The reliability allocation of machine tools which is a multi-attribute decision-making problem has great significance in designment of machine tools. This paper integrates the intuitionistic trapezoidal fuzzy numbers and performance sorting technique based on similar ideal solutions to achieve the flexible allocation of machine tools reliability. Firstly, intuitionistic trapezoidal fuzzy numbers are

A Correction to this paper has been published: https://doi.org/https://doi.org/10.1007/s00170-021-07377-9

Various countries in the world have issued policies on smart manufacturing and put forward relevant system architecture, including its hierarchy and component elements. However, from the perspective of implementation, it is necessary to further expand and study the relationship between the elements of the framework and the specific application scenarios. The focus of this study is to plan the specific

This paper is focused on double-sided self-pierce riveting (DSSPR) of overlapped sheets made from dissimilar materials with very different mechanical strengths. The methodology draws from previous work on sheets made from similar or identical materials and the extension to dissimilar materials is built-upon a combined experimental and numerical investigation that makes use of AA5754-H111 aluminum and

In applications requiring large specific surface area, ultrathin walls fabricated by selective laser melting (SLM) have attracted wide attention. Understanding that the geometric characteristics of ultrathin walls are affected by process parameters is an important topic. To investigate the influence of SLM process parameters on geometric morphology, interlayer banding characteristics, and defects of

The coating effect on the cutting temperature has long been a hot topic in understanding heat transfer mechanism in machining coated tools, and especially the multi-layer coated tools. For multi-layer coated tools, the coating structure, coating thickness, and coating material will affect the cutting temperature of the tools. This paper is devoted to the cutting temperature in dry turning of H13 hardened

Parts manufactured by wire and arc additive manufacturing (WAAM) can have significant deformation and large dimension errors. To overcome these problems, a self-made forced cooling device for arc constricting (FCDAC) is designed and used in cold metal transfer arc-based WAAM to constrict the arc shape, further to improve the forming quality, and especially to control wall thickness. The experimental

The defects and rejections caused by the combined action of thrust force and cutting heat impede the wide application of carbon fiber-reinforced plastic (CFRP). To study the cutting temperature of two kinds of tools in the orbital drilling of CFRPs, a cutting force model and a heat transfer model were proposed in this research. The three-dimensional heat transfer equation in polar coordinates was established

In this paper, the reliability allocation and index of overall cost of rotary ultrasonic vibration-assisted EDM machine tool were studied. The failure rate of each module of the rotary ultrasonic vibration-assisted EDM machine tool can be accurately predicted by the maximum entropy ordered weighted average algorithm so that the corrected maintenance cost can be predicted. And effective control of preventive

Automated dimensional inspection is commonly expensive because of the requirement of high-precision measurement devices. To perform a precision measurement, the technician must be highly skilled and fully understands the operation of the equipment. This study proposes a method for reconstructing the two-dimensional profiles of ring-shaped objects using image processing. At first, an industrial camera

In the routine roll shifting mode, work rolls of the continuous variable crown (CVC) hot strip mill are always in repeated shifting positions, which affects the uniform wear of work rolls. As an available solution to the above problem, a new random shifting mode for CVC work rolls has been developed in this paper. According to the relationship between shifting position and bending force, the new CVC

A correction to this has been published https://doi.org/10.1007/s00170-021-07309-7

Nowadays, manufacturing systems should be cost-effective and environmentally harmless to cope with various challenges in today’s competitive markets. This paper aims to solve an environmental-oriented multi-objective reconfigurable manufacturing system design (i.e., sustainable reconfigurable machines and tools selection) in the case of a single-unit process plan generation. A non-linear multi-objective

Especially for slicing hard and brittle materials, wire sawing with electroplated diamond wires is widely used since it combines a high surface quality with a minimum kerf loss. Furthermore, it allows a high productivity by machining multiple workpieces simultaneously. During the machining operation, the wire/workpiece interaction and thus the material removal conditions with the resulting workpiece

Compared with the conventional drilling, the helical milling has obvious advantages in making holes of carbon fiber-reinforced plastic (CFRP). Nevertheless, the rapid wear of cutting edges readily causes some defects in the outlet holes, such as burrs and tearing. In order to improve the hole-making quality of CFRP, a comparative experimental study on conventional and ultrasonic-assisted bi-directional

A further increase in the efficiency of low-temperature plasma modification of the metal product surface layer is possible on the basis of the process supervision. The article presents an approach and a developed model that allows to receive and study the behavior of signals arising in the electrical circuit of a technological unit under the interaction of electromagnetic and electrostatic fields that

Aiming at the assembly sequence planning (ASP) of complex products, the evaluation system for the geometric feasibility, priority constraint, aggregation, redirection, and stability of the assembly sequence was considered. An assembly sequence planning method based on adaptive gravitational search algorithm (AGSA) is proposed. It includes building a mathematical model of algorithm optimization and

Thin-walled parts are widely applied in the automotive and aerospace industry for their superior properties. However, severe machining error may occur due to their low rigidity under the effects of multiple error sources in the machining process. Solutions based on mechanism analysis and finite element method have been developed while most of them are not robust under the complex machining conditions

As the core machining process element in the overall manufacturing process of a part, the machining process route plays an important role in improving final manufacturing quality. In the current CAPP system, the decision-making of the process route still depends on human-computer interaction and essentially depends on human intelligence. In the past decade, deep learning technology architecture has

As-built metallic parts manufactured by the laser powder bed fusion (LPBF) process are usually associated with distortions and high residual stresses due to the high thermal gradients and cycles during the process. Finite element modeling (FEM) could be helpful in simulating the build process and predicting the thermally induced residual stresses and parts’ distortion during or after the process, or

When machining the parts, an unwanted buildup formation often appears on the working surface of a tool. As a result, dimensions and geometry of the working part of the tool change. The roughness of the machined surface and pulling force increase and unwanted vibrations appear. The work objective was to determine the possibilities of limiting or total elimination of the buildup forming. The research

The main goals of this study were the development of new composites of construction materials from three types of construction industry wastes: construction and demolition debris, plaster waste, and lime production waste; determination of the physical-chemical processes of new composites structure formation. The study was using the methods of X-ray powder diffraction, scanning electron microscopy,

In nanometric cutting, the dominant material removal mechanism can be greatly different with macroscopic cutting process. In this work, molecular dynamics (MD) simulation was carried out to investigate the cutting features of single-crystal silicon. The effect of the tool rake angle and the workpiece crystal orientation on the transition of the material removal mechanism was studied. Theoretical analysis

Aluminum alloy can obtain good forming effect and strength after age forming. The addition of an ultrasonic field in the two-stage age forming process could have a positive effect on the forming performance and microstructure. In this study, we aimed to combine the ultrasonic vibration and two-stage age forming. The application of ultrasonic waves could reduce the rebound rate of aluminum alloy component

This paper presents the cognitive module of the Cognitive Architecture for Artificial Intelligence (CAAI) in cyber-physical production systems (CPPS). The goal of this architecture is to reduce the implementation effort of artificial intelligence (AI) algorithms in CPPS. Declarative user goals and the provided algorithm-knowledge base allow the dynamic pipeline orchestration and configuration. A big

Metal powder bed fusion in additive manufacturing is gaining interest as a manufacturing technique for complex metal parts in the aerospace, rail, and automotive industries. This has led to an emergence of 3D printers in the market to accelerate the diffusion of this technology as an industrial manufacturing technique. The Aeroswift is an additive manufacturing machine developed with the purpose of

Human-robot collaboration as a multidisciplinary research topic is still pursuing the robots’ enhanced intelligence to be more human-compatible and fit the dynamic and stochastic characteristics of human. However, the uncertainties brought by the human partner challenge the task-planning and decision-making of the robot. When aiming at industrial tasks like collaborative assembly, dynamics on temporal

In this work, formabilities of aluminum sheet alloy grade AA5052-H32 were investigated under consideration of the anisotropic behavior of material. Experimental tensile tests and modified Marciniak in-plane stretch-forming tests of sheet samples with varying shapes were performed for different sample orientations. The critical fracture strains at various states of stress were gathered by means of a

Machining of CFRP composites is usually described as a challenging process from tool life and surface quality perspectives. To achieve a flawless machined surface at reasonable cutting tool life/cost, an optimum combination of cutting tool material and geometry is the key. The cutting tool angles are of importance as these dictate the cutting mechanism as well as the cutting edge robustness and the

The central deformation extent of the thick plate can be improved and the approaching uniform deformation will be realized by the snake/gradient temperature rolling (SGTR). At present, the existing rolling force analytical models cannot be directly used for SGTR because of the great difference with the synchronous rolling. The rolling force model should be established so as to meet the production demand

In this work, the unique plastic deformation behavior of T2 rolled copper foils under ultrasonic impact (UI) and ultrasonic rolling (UR) has been studied systematically. The numerical simulation and test results show that with the decrease of the thickness of copper sheet, the equivalent plastic strain (PEEQ) value and plastic strain εp formed by UI or UR increase exponentially, and its distribution

In order to further improve the surface quality of electrochemical machining multi-stage internal cone hole parts, the method of rotating magnetic field–assisted electrochemical machining is proposed in this paper, a new cathode structure which inlaid Nd-Fe-B permanent magnet on the side wall was designed, and the simulation study on the effect of the magnetic field on the uniformity of the flow field

The magnetized sintered NdFeB (MS-NdFeB) permanent magnet material is difficult to machine due to high hardness, brittleness, and magnetic force. In this paper, the electrical discharge machining (EDM) of the MS-NdFeB workpiece is studied to improve the machining process of the MS-NdFeB. In addition to the material removal rate (MRR) and the surface roughness (SR), the change rate of the magnetic flux

Aiming at the problem of low machining efficiency caused by the constant feedrate set by craftsmen in CNC machining, a feedrate optimization method by effectively combining the allowance optimization and the constant power constraint is developed in this paper. Firstly, the paper presents a machining allowance optimization method and corresponding hierarchical solution strategy to calculate machining

To study the transverse temperature uniformity with transverse flux induction heating (TFIH) during endless strip production (ESP) rolling, a coupled electromagnetic-thermal finite element model of transverse flux induction heating is established. The initial temperature distribution at the TFIH inlet is taken into consideration, which is the basis of subsequent numerical studies. Magnetic screens

A shaver cap is a typical thin-walled rotational part, and the processing performance of its torus surface has an important impact on the cutting efficiency, sharpness and working noise of the shaver. Electrochemical face grinding (ECFG) is a promising machining method in the fabrication of difficult-to-cut thin-walled parts. However, the flow field distribution in the interelectrode gap can vary,

Due to the complex metal flow in the cold extrusion of sun gear, the teeth accuracy of formed sun gear is poor. In order to improve the accuracy of extruded sun gear, a precision sizing method was proposed in this study. Finite element simulation for predicting tooth deviations of finished sun gear was performed using DEFORM, and the influences of key process parameters such as the sizing amount of

The machined surface topography of workpiece plays an important role in the performance and service life of workpiece. At present, the study of milling surface topography is mainly on 3-axis milling with ball end mill. Also, in 4/5-axis milling, surface topography analysis is mainly on the experimental data. In order to solve this problem, an analytical prediction model of milling surface topography

The mechanical analysis and deformation mechanism of cap formation in orbital drilling process plays a vital role in revealing the changing law of hole-making quality at the exit machining stage. The characteristics of cap formation, generated by a dedicated cutting tool, is proposed that aimed at orbital drilling process. Especially, the cap bottom is simplified as a simply supported circular plate

Acceptance sampling is popular in industries to determine whether a submitted lot should be accepted or not. Various sampling plans have been developed under the assumption that the quality characteristic of a product follows a normal distribution. However, lifetime data generally follows a non-normal distribution, such as exponential, gamma, or Weibull distribution in many applications. Therefore

The improvement of ultra-precision machining technology has significantly boosted the demand for the surface quality and surface accuracy of the workpieces to be machined. However, the geometric shapes of workpiece surfaces cannot be adequately manufactured with simple plane, cylindrical, or spherical surfaces because of their different applications in various fields. In this research, a method was

It is easy to obtain the near-polished grinding surface using fine-size grain diamond wheel (such as #2000, grain size 6.5 μm) and a small grinding depth. However, a relatively big-size wheel (such as #600, grain size 24 μm) is difficult to accomplish the near-polished grinding. Hence, this paper proposes a novel axis-feed grinding approach with the assistant of pure CeO2 atomizing liquid to obtain

This study aimed to understand the effects of core configuration on the mechanical properties of additively manufactured specimens made of commercial wood/PLA filament through 3D printing. The wood/PLA specimens with different infill rates and pattern types, such as square, hexagonal, and octagonal, were manufactured using a 3D printer. The process parameters in the production of the 3D-printed specimens

A novel ice particle-fixed abrasive tool (IPFAT) was designed and manufactured in this paper. The uniformity of abrasives distribution in the IPFAT was tested. Using three kinds of IPFAT, which contains α-Al2O3 particles whose mean particle sizes are 5 μm, 1.289 μm, and 0.328 μm respectively; single crystal germanium wafers were lapped and then polished. The results show that the distribution of abrasives

As an important forming parameter, the influence of punch-die clearance on thick plate blanking has been extensively discussed. In contrast, the analysis and prediction of metallic foil blanking are more difficult due to the size effect caused by thickness reduction. To explore the clearance effects at a meso-scale, a series of blanking tests of 304 stainless steel foils with 100 μm thickness were

Wire arc additive manufacturing (WAAM) is well suited for the manufacture of sizeable metallic workpieces featuring medium-to-high geometrical complexity due to its high deposition rate, low processing conditions limit, and environmental friendliness. To enhance the current capability of the WAAM process for fabricating structures with complex geometry, this paper proposes a robot-based WAAM strategy

Positive displacement motor is a widely used downhole power drilling tool. In order to solve the problems of short life of conventional positive displacement motors and difficulty in processing micro-sized positive displacement motors with equal wall thickness, this paper proposes to use the liquid filling and external extrusion composite forming process to process the tiny size spiral tube with equal

In this study, relationships among process parameters, traverse and rotation speed, and the corrosion resistance at stir region of friction stir welded joints of aluminum alloy AA5052-H32 were evaluated, which were obtained using a tool with featured shoulder and threaded pin. Corrosion analysis was carried out using open circuit potential (OCP) potentiodynamic polarization curves and electrochemical

In machining processes, various phenomena occur during cutting operation. These phenomena can disturb the production through the reduction of part quality and accuracy. An easy way to control the process is by monitoring incontrollable parameters, such as generated temperature and vibration. The acquired vibration signals can provide information regarding tool life, surface roughness, cutting performances

The MCAW with rotating electrode process (MCAW-RE) is a variation of the conventional MCAW (metal-cored arc welding) process, where reduced costs and superior productivity are obtained due to narrow gap welding, since the rotational motion of the electrode allows the electric arc to reach peripheral regions of the groove, preventing lack of fusion on the sidewall. Although there is some information

In recent years, SiCp/Al metal matrix composites (MMCs) have attracted increasing attention from academia and industry. The size and distribution of particles in this material have an important effect on its actual performance. First, the geometric analysis of milling is performed. A two-dimensional micro finite element model consisting of hard SiC particles and a soft aluminum matrix is established

Features of the electric power market functioning, in comparison with common properties of modern markets, are considered. It is shown that continuous reforms, which take place in many countries, are far from reaching effective solution. Sectoral peculiarities, connected with both technological complexity of the field and economic specificity of the market participants, form very special model of the