This article has been retracted. Please see the Retraction Notice for more detail: https://doi.org/10.1007/s00170-020-06547-5

Insulated faux brick (IFB) is an improvement on traditional faux brick that aims to further reduce weight and installation time while providing insulation characteristics beyond traditional brick. Current production of insulated faux corner bricks relies on human workers to apply adhesive and press together two end pieces until the adhesive has dried. This is a time-consuming step which is not easily

To find a robust combination of selective laser melting (SLM) process parameters to achieve the highest relative density of 3D printed parts, predicting the relative density of 316L stainless steel 3D printed parts was studied using a set of machine learning algorithms. The SLM process brings about the possibility to process metal powders and built complex geometries. However, this technology’s applicability

AerMet100 steel is a typical difficult-to-cut material, and laser-assisted milling (LAM) is a promising machining technology for this kind of material. In LAM process, the material is softened by the thermal effect of laser beam, which improves the machinability of the materials. And finally, the cutting forces are reduced compared with conventional milling (CM). This paper presents an analytical model

Drilling using quasi-continuous wave (QCW) millisecond pulse fibre laser is the state-of-the-art for producing film-cooling holes over uncoated aero-engine components. Laser drilling of coated components, including thermal barrier coated (TBC) components, is still a challenging task due to the risk of coating delamination. Water-jet guided (WJG) laser is nowadays increasingly used for machining of

In conventional shape tolerance design, allowable ranges are given for the assembly joint surfaces. The conventional method does not restrict the distribution form of the actual errors of surfaces, resulting in a large deviation in the prediction of assembly performance (i.e., geometric accuracy and mechanical property) from those of actual state. In order to obtain the best performance of product

Metal powder hot embossing (MPHE) is a low-cost micromanufacturing technique that can produce metallic parts with aspects in micron scale. In this study, scanning electron microscopy (SEM) is employed for evaluating the shape retention and the homogeneity of microstructure of replicated geometries into AISI 316L powder feedstock by the secondary electron imaging (SEI) and the backscattered electron

Induction hardening, a promising approach for selective hardening of metal parts, is widely used for surface hardening, where a hard surface is required alongside a tough core. Regarding the complexity of this process, parts’ geometry deeply affects the temperature distribution and hardness profile accordingly. In this study, two magnetic flux concentrators are introduced to our induction machine set

The position or movement control of an automated guided vehicle (AGV) is crucial for its operation. However, choosing the AGV position sensor is not a trivial task. This paper investigates the sensors and sensing techniques in machine vision applied in AGV position control in the past 5 years of published academic research. Using a systematic literature review method, we seek to answer the main research

Indirect methods to monitor the surface integrity of grinding wheels by acoustic emission (AE) have been proposed, aiming to ensure their optimal performance. However, the time-frequency analysis of the content of these signals has not been addressed in the literature. AE signal analysis performed only in the frequency domain makes it impossible to locate faults on the grinding wheel surface during

The casing is a basal body part for assembling other parts in an aeroengine, but its weak rigidity seriously affects machining accuracy and production efficiency. Therefore, it is very important to improve this rigidity of the part during processing. An aeroengine combustor casing is used to study the vibration law and suppression method of a casing milling process through a combination of simulations

For thermal perception and control onto spindle bearings without spindle/bearing structural modifications for built-in thermal sensors, this paper proposes a thermal simulation speculation-based active coolant control strategy onto spindle bearings, for spindle accuracy guarantee. Firstly, numerical simulation technology is adopted to construct thermal collection of spindle bearings influenced by coolants

In this paper, a novel lean approach to address material losses in production processes is presented. It is termed materials cost deployment (MaCD) and has the objective of identifying, analyzing, and reducing or eliminating material losses. Thanks to the modification of the manufacturing cost deployment framework, MaCD proposes an alternative structure for classifying and analyzing material losses

Hydrogen and micropores are widely distributed and inevitable in heavy forgings. The accumulation of hydrogen in micropores results in the formation of higher hydrogen pressure inside. In this article, the influence of heating process on hydrogen behavior around micropores is studied by finite element method. The analysis model is established theoretically and the relationship among micropore hydrogen

Owing to the advantages like high specific strength, high heat resistance and excellent wear resistance, carbon fiber reinforced polymers (CFRP) are used widely in the aerospace field. Nevertheless, due to shortcomings such as anisotropy and uneven phase distribution, the cutting failure behavior of CFRP includes a series of complex processes like fiber delamination and matrix fracture, which are thus

The unique combination of corrosion resistance, mechanical properties, and biocompatibility have made commercially pure titanium (CP-Ti) widely used as bio-implant materials. The bio-implant requires high-quality surfaces, with specific characteristics for each utilization. Due to high temperatures in the cutting zone and the high chemical affinity, titanium is usually machined with cutting fluid.

Manual surface inspection methods performed by quality inspectors do not satisfy the continuously increasing quality standards of industrial manufacturing processes. Machine vision provides a solution by using an automated visual inspection (AVI) system to perform quality inspection and remove defective products. Numerous studies and works have been conducted on surface inspection algorithms. With

Belt grinding is a widely adopted method in processing titanium alloy materials. However, its unique grinding mechanism will greatly affect grinding efficiency. Meanwhile, in order to finish processing task, adopting the method of replacing belts frequently will further make processing time, cost, and energy consumption rise, as well as the pollution during the whole processing. Considering the problems

With the current tendency of mass production towards customer-oriented serial production, blanking processes are facing new challenges. They require an increase in knowledge about faulty process conditions and their influence on the quality of a component as well as an instruction for a target-oriented adaptation of the process. The aim of this study is therefore to identify property deviations based

The implementation of a PLM is a great process of change, representing a critical phase due to the inertia that characterizes some organizations. This evidence especially occurs in industry new to PLM, such as the fashion one, where a lack of clear guidelines for implementation significantly increases the risk of failure of that process. In addition, an adequate project management approach that actively

Compacted graphite iron (CGI) is an ideal material for the cylinder block and cylinder head of diesel engine because of its excellent physical and mechanical properties. At present, the researches on CGI mainly focused on experimental study of machining CGI, there are few studies on the cutting simulation of CGI, especially the high-speed machining simulation of CGI, and the constitutive equation of

The effects of magnetizer parameters on the temperature field of high-strength steel blanks are investigated through the combination of experiment and simulation. An electromagnetic-temperature three-dimensional finite element model is simulated. Numerical simulation indicates the spacing in the width direction significantly affects the temperature field of steel blanks, and the optimal spacing of

Using multi-axis tool paths in combination with a structured segmentation strategy introduces novel fabrication solutions for the direct energy deposition additive manufacturing process. However, with a piecemeal manufacturing strategy, interface regions are introduced. The goal of this research is to determine whether utilizing a multi-stage, multi-axis build strategy has an impact on the resulting

Severe plastic deformation processes (SPDs) have been developed over the past decades to produce bulky parts with proper mechanical and microstructural properties. Equal-channel angular pressing (ECAP) is a method in which a metal is subjected to severe plastic straining through simple shear. The combined extrusion-equal channel angular pressing (C-Ex-ECAP) is proposed in this paper as a new method

In the search for thermal management of advanced avionics packaging, materials such as eutectic liquid metal (LM) alloys and synthetic ceramics with superior thermophysical properties offer reliable and effective solutions. Conductive ceramic tubes can be used to contain LM as a coolant for heat exchangers. However, conductive ceramics will still need to be combined with metals to provide optimal thermal

Shot peening is a major finishing treatment aiming to enhance parts’ life. However, the recourse to simulation to master the process and its effects still suffers from problems due to its complexity. The current paper presents a finite element-based approach that considers the random aspect of the shot peening process in association with a large number of shots, making it more realistic. The developed

The processing parameters directly affect the polishing quality of planar optics in chemical mechanical polishing (CMP). In this paper, a novel multiparameter optimization method based on the fuzzy theory was proposed to evaluate the manufacturing efficiency and accuracy of flat optical elements with CMP. The evaluation criteria and optimized parameters for CMP optimization were selected. The optimized

A conformal cooling channel (CCC) is widely employed in the injection mold due to uniform cooling. The cooling efficiency of the epoxy resin mold (ERM) strictly depends on the thermal conductivity since the cooling time directly affects the productivity. According to the practice experience, the material cost of commercial aluminum (Al)-filled epoxy resin is high and the cooling efficiency of the injection

Powder bed fusion (PBF) process is expeditely moving towards its maturity for the direct manufacturing of intricated and sophisticated metallic parts. The typical process is instead complex and yet challenging to interpret experimentally. Modeling and simulation strategy has been widely implemented to comprehend and optimize the process. Therefore, an integrated simulation approach incorporating stochastic

High-speed 3D printing has recently gained much interest due to its potentials in improving efficiency of fabricating complex geometry components and applications in large-scale additive manufacturing (AM). In this study, a parametric study is performed experimentally to investigate factors affecting high-speed 3D printing of continuous carbon fiber reinforced composites (CFRCs), including material

In the previous studies about grinding simulation, most of the abrasive grain models are simple geometries. The shape and size of the abrasive grain are varied, which will lead to the difference between the simulation and the reality. To make the virtual abrasive grains closer to reality, a stochastic polyhedral abrasive particle modeling method based on the ellipsoid tangent plane is proposed. Based

This work aims to review literature related to the latest cyber-physical systems (CPS) for manufacturing in the revolutionary Industry 4.0 for a comprehensive understanding of the challenges, approaches, and used techniques in this domain. Different published studies on CPS for manufacturing in Industry 4.0 paradigms through 2010 to 2019 were searched and summarized. We, then, analyzed the studies

Warm laser shock peening (WLSP) is a novel surface modification technology involving a combination of laser shock peening (LSP) and dynamic strain aging (DSA) technologies. Nickel-based single-crystal superalloy is one of the leading materials for aeroengine turbine blades. Hence, studying the surface modification effect of WLSP on [001]-oriented DD6 nickel-based single-crystal superalloy has a real

Severe tool wear is always considered as a main negative result in the process of drilling Ti-6Al-4V alloy. Although the idea of employing one-dimensional longitudinal ultrasonic vibration in the drilling process to reduce tool wear has been proposed for many years, studies on longitudinal-torsional composite ultrasonic vibration–assisted drilling (LT-UAD) are seldom reported. LT-UAD is a hybrid machining

The gear slicing technology has a wide range of applications, not only for involute gear but also for non-involute gear such as circular arc. Previous research shows that gear slicing is very suitable for the production of an RV reducer with high efficiency and precision. In view of this, a design method for slicing cutter is proposed aiming at the circular arc tooth in pinwheel housing of an RV reducer

Nanomaterials such as graphene have been added to various matrices to enhance mechanical, thermal and electrical properties for various applications requiring intricate designs at the micro-scale. At this scale, mechanical micro-machining is utilised as post-processing to achieve high surface quality and dimensional accuracy while still maintaining high productivity. Therefore, in this study, the machinability

Hexagonal boron nitride (h-BN) is an excellent solid lubricant that can be used to improve the processability of difficult-to-cut materials. We tried to solve the processing difficulty of vermicular graphite cast iron (VGI) by adding 0.0144 wt% of h-BN micro-powders into VGI (tensile strength Rm ≥ 450 MPa). Then, we use coated cemented carbide tools (CCC tools, coatings TiC + Al2O3) to carry out the

Flexible stretch-bending of multi-point roller dies technology is a new three-dimensional forming technology for profiles. Compared with the traditional stretch-bending process, the three-dimensional deformation of the profile can be formed at one time, and the cost of the die is greatly reduced and the production efficiency is improved. The die is an important component of flexible stretch-bending

Incremental sheet forming was developed several decades ago as a cost-effective forming process for low volume production. The deformation mechanism of this process is completely different from the conventional sheet metal–forming processes. Applying a three-dimensional (3D) yield function such as Yld2004-18p for the simulation of incremental sheet forming is necessary to account for the significant

To control part quality, it is critical to analyze pore generation mechanisms, laying theoretical foundation for future porosity control. Current porosity analysis models use machine setting parameters, such as laser angle and part pose. However, these setting-based models are machine dependent; hence, they often do not transfer to analysis of porosity for a different machine. To address the first

SiO2 ceramic has wide applications in various industries owing to their excellent properties. To make the most use of their properties and enlarge their applications, it is important to bond the SiO2 ceramic and metal. The brazing of SiO2 ceramic in recent years is reviewed in this article. The advantages and disadvantages of the active brazing method are discussed. The bonding between SiO2 ceramic

The processing efficiency of dentures is generally quite low due to the complex profile form and high brittleness of the dentures. However, there is little research for efficient path optimization and look-ahead speed control algorithm in denture machining field, which hinders the improvement of the machining efficiency and denture quality. In this work, an optimization method for both straight transition

This study provides an optimal shape of square nut for better projection welding performance. Both experimental design method and electrical-thermal-mechanical finite element analysis (FEA) are used to investigate the effects of nut shape parameters on the height decrease of nut leg, called setdown. The relationship between the setdown and weld strength is then analyzed. Also, welding time to reach

A Correction to this paper has been published: https://doi.org/10.1007/s00170-021-06648-9

This paper, on the basis of error modelling, proved the optimal pocket machining sequences of a simply end supported pocketed beam using mathematic induction method. The optimal pocket machining sequence with the minimum pocket floor height error is the machining from both ends to the middle and the optimal sequence is not unique because of the symmetric supports about the central plane; meanwhile

Interpolators play a core and important role in CNC systems, and the scheduling of feedrate is a main task of CNC interpolators. It is routine to schedule the feedrate of linear/circular toolpaths because of their regular geometry; however, the feedrate scheduling of spline toolpaths remains challenging due to the freely and unpredictable geometric shape. Most of the existing methods require looking

Friction stir spot welding was successfully applied to the 1.4 mm thick galvanized DP590 dual-phase steel plates using a W-Re alloy rotating tool. During welding, a constant rotation speed of 800 rpm and a dwell time of 3 s were used and the tool penetration depth was ranged from 0 to 0.9 mm in order to study the flowing behavior and distribution of the Zn element in the joints. It was revealed that

As one of the vital technological factors influencing the machining quality, machine tool fixture has been regarded as an important research object by scholars at home and abroad. In this paper, a new method for rapid evaluation of clamping scheme was presented based on the study of machining deformation of aerospace complex thin-walled parts. Firstly, Through the modal analysis of the thin-walled

The quality of holes machined in carbon fibre reinforced plastic is vital to the strength of CFRP/Ti stacks. In this study, the influence of cutting temperature upon hole damage of CFRP in CFRP/Ti stacks under helical milling was compared with and without the presence of an underlying Ti. The cutting forces, exit quality, wall surface and subsurface quality of CFRP hole were analysed. And proposing

This paper presents a milling force model for carbon fiber-reinforced polymer (CFRP) multidirectional laminates based on segmented specific cutting energy. The proposed model simplifies the milling process of CFRP unidirectional laminates into multiple orthogonal cuttings. The CFRP specific cutting energy was determined by experimental segmentation. An empirical formula for the CFRP segmented specific

KDP crystal is an important functional crystal material used in the fields of laser frequency conversion. Slicing is the first process of KDP crystal processing and the KDP crystal is usually sliced by the diamond wire saw. As KDP crystal is an anisotropic material, the properties of KDP contact with different diamond grits on the diamond wire saw during slicing would be different. The anisotropic

Composite structures play an important role in realising resource-efficient products. Their high lightweight potential and improved manufacturing technologies lead to an increased use in high-volume products. However, especially during the design and development of high-volume products, the consideration of uncertainties is essential to guarantee the final product quality. In this context, the use

Micro-electrical discharge machining (μEDM) is an unconventional machining method that is suitable for machining of conductive materials including highly doped silicon (Si) wafers. This paper reports a novel method of heat-assisted μEDM machining of Si wafers by varying the temperature to increase the electrical conductivity of Si. In order to achieve this condition, a ceramic heater is used to heat

In this paper, mechanical properties and microstructural feature of magnetic pulse welding joint between Cu and Al sheets were investigated. The qualities of Al/Cu (Al acted as a flying plate) and Cu/Al (Cu acted as a flying plate) joints were analyzed by lap-shear tensile test and microstructure observations. The welding process was simulated by LS-DYNA to observe the changes in physical parameters

Tool wear inevitably occurs during electrical discharge milling (ED milling), adversely affecting the form precision of machined features. Specifically, radial tool wear negatively influences copying precision. In this study, electrical discharge ablation milling (EDA milling) with a microcutting depth was investigated to improve the machining precision of discharge milling. In the proposed method

The paper details a comprehensive experimental investigation on the influence of operating parameters and cut direction (parallel and perpendicular to fibre orientation) when wire electrical discharge machining (WEDM) unidirectional CFRP composites using zinc-coated brass wire (0.25-mm diameter). A Taguchi L18 fractional factorial orthogonal array considering four variable parameters including open

Titanium alloy Ti-6Al-4V is extensively employed in aero-engine as blade, disk, and casing components, which have a high risk to occur fatigue failure. The milled subsurface damage is one of the critical factors influencing fatigue property. This paper has a comprehensive overview on the subsurface damage in titanium alloy Ti-6Al-4V induced by milling. It was found that the milled subsurface damage

In the multi-pass conventional spinning process, roller paths have a significant influence on the forming quality of formed parts. The variations of the cone angle of the curvilinear generatrix part make roller path planning difficult. Current researches mainly focus on the design of the roller path profiles and its influence on the wall thickness uniformity of the parts in the one-pass spinning process

During the manufacturing of fibre-reinforced laminates, undesired phenomena are produced, among which the residual stresses need investigation and analysis. The authors have previously presented the research done on the predictive modelling and measurement of the distortions happening during the manufacturing of fibre metal laminates (FML). In this paper, primary measurements of residual stresses are

Compared with the traditional abrasive flow, cavitation abrasive flow can effectively improve the kinetic energy and motion randomness of abrasive particles during the polishing process without changing the polishing pressure, thus reducing the scratch and damage caused by hard and large particles on the surface and subsurface of monocrystalline silicon, and efficaciously improve the surface quality