Digital techniques are a strategic tool to design new commercial products, reducing time and waste. This is particularly relevant for shoe manufacturing and, in particular, for high-heeled shoes, for which a trade-off between comfort and attractiveness is difficult to achieve. This paper offers a new set of tools to design high-heeled shoes that exploits the synergies between modeling and experiments

This study fabricates a roughing electrode of electrical discharge machining (EDM) using a rapid prototyping (RP) system and investment casting technology, which reduces the overall time that is required for fabrication and the cost of the manufacturing process for a selected electrode. Pro/E (3D CAD) software is used to design the electrode prototype, which has a complex appearance, and to transform

Plastic instability of mechanical bulging process, different from the traditional tube hydroforming, is developed for Zircaloy tube based on localized necking criterion. Based on the observation of published experiments of bulging, an elementary analyzed model of plastic deformation is proposed and applied for examining the variation of bulging process and its limitation. The developed model comprises

Multi-direction loading forming technology provides an effective way for green manufacturing of high-performance multi-cavity complex parts of 316LN steel, which are widely used in nuclear power pipelines. In this forming process, the material needs to undergo complex unequal deformation under a mixed stress state of tensile-shear, compression-shear and shear, flow and fill the cavity to obtain such

The proper implementation of sustainable manufacturing processes is an effective step towards a clean environment. The modern cooling strategies applied in the manufacturing sector have presented promising solutions that enable economic growth and ecological environment. In machining operations, cryogenic cooling and minimum quantity lubrication (MQL) have been extensively utilized to replace conventional

The structural vibration and dominant vibration characteristics of the machining process of machine tools have an important influence on the machining quality and efficiency. The dominant vibration characteristics are related to two factors: the dynamic characteristics of the machine tool structure and the excitation characteristics of the system. In the dynamic process of structural vibration, the

Directed energy deposition (DED) is an additive manufacturing (AM) process where a laser is used to fuse a metal powder onto a substrate. The powder is deposited in a layer-by-layer fashion, and each deposited track is referred to as the clad. Large thermal gradients that occur during DED can cause changes in the clad geometry as well as deformation of the substrate and final part. Thermal behavior

Firstly, simulation is used to analyze the temperature curve in pre-stress hardening grinding (PSHG). Then, according to the start and the end time of martensitic transformation, three time nodes are selected to study the pre-stress time characteristic; they are 1 s, 3 s, and 7 s after grinding. The influence of pre-stress on the initial temperature and content of martensite transformation in cooling

Inconel 718 (IN-718) has excellent mechanical and chemical properties at high temperature, which has been widely applied in aerospace, ocean, and chemical industries. Meanwhile, the super high temperature properties lead to its poor machinability and machined surface integrity. Good machinability and surface integrity of IN-718 have always been challenging topics in the field of mechanical machining

High-performance aluminum alloy is light, has high strength, but is very difficult to be formed. In the forming process of aluminum alloy parts with special-shaped bottom, there are defects such as poor fittability accuracy, instability, and cracking at the complex bottom, and the forming accuracy is an important performance index to characterize the forming quality. In this paper, a precision warm

During high-speed machining of aeronautical monolithic components, the initial residual stresses will cause the workpiece deformations with the removal of material. Therefore, it is crucial to investigate the prediction and control of workpiece deformations for the achievement of a machining process with high efficiency and precision. Above all, the mechanical model is established for the deformation

In machining processes, the friction and frictional stress formation along the interface between the chip and the tool rake face give rise to energy consumption, tool wear, and failure. This study aims to investigate the influence of tool nomenclature (radial rake angle) and cutting conditions (spindle speed and table feed velocity) on the impediment of friction and frictional stress in the perspective

A novel multielectrode multiloop with series capacitance (MEMLSC) pulse generator is developed to improve the machining efficiency of electrical discharge machining (EDM). In the multielectrode discharge circuit system, each electrode is connected to an independent discharge circuit and forms a singular discharge loop with a common workpiece. A capacitance is serially inserted between each electrode

Cutting force is the predominant output variable in rotary ultrasonic machining (RUM). It dictates other output variables, such as tool wear, cutting temperature, edge chipping, etc. It is desirable to develop a mechanistic model to predict cutting force and reveal the underlying cutting tool-workpiece interaction in RUM. Numerous researchers have developed theoretical approaches to predict cutting

The tribological performance of a machined surface is greatly influenced by the quality and reliability of manufacturing processes employed in its creation. In the present study, an attempt has been made to investigate the effects of various cutting parameters which include cutting speed, feed rate, depth of cut, and ultrasonic vibration amplitude on surface tribological characteristics of C45 carbon

Large tensile residual stress is detrimental to the structural integrity of welded structures. As a result, it is very important to understand the residual formation during the welding process. In this paper, a new non-contact welding residual stress measurement technique based on digital image correlation (DIC) is proposed as a way to investigate residual stress formation. To investigate the stress

Research in vision systems applied to manufacturing processes has increased during the last years. Nevertheless, accurate positioning systems frequently require costly investments. This article presents a new algorithm developed in LabVIEW for controlling a novel positioning system that processes images to obtain the position, which could be implemented in micromachining. With this aim, the method

To understand intuitively the residual stress state on the rail surface after abrasive belt rail grinding (ABRG), the influences of grinding process parameters on residual stress were experimentally investigated on the ABRG test bench. Tensile residual stress was found in the grinding direction, while the residual stress in the radial direction was maintained mainly in the form of compressive stress

The final quality of mechanical components is directly linked to the efficiency of the machining processes to which it is subjected. In this sense, grinding can provide high standards of surface and geometric quality for mechanical components, since these characteristics are increasingly necessary for the automotive and aerospace sectors. However, the complexity of the mechanical components creates

Sustainability is a key factor in an automotive OEMs’ business strategy. Vehicle electrification in particular has received increased attention, and major manufacturers have already undertaken significant investments in this area. However, in order to fully confront the sustainability challenge in the automotive industry, lightweight design in additional to alternative propulsion technologies is also

Demand in 3D printing products using fused filament fabrication (FFF) in industry has been growth a lot with 55% in development of prototypes, 43% in production, and 41% in conceptual models for testing. However, information regarding the manufacturing considerations of geometry-restricted components is still an opportunity area, generating printed components with quality defects. This article is aimed

The spindle barrel finishing is commonly used to improve the surface integrity of the important parts of the high-end equipment while it is difficult to provide enough test artifacts for the traditional trial and error experiment to obtain the desirable processing technology. The EDEM simulation of the spindle barrel finishing can provide effective help for the process design. In this paper, simulations

Aramid fiber–reinforced plastic (AFRP) composites have been widely used in automotive, aerospace, and defense industries. The common AFRP drilling process tends to cause damage to the composite structures which subsequently affects their fatigue lives and in-service performance. Understanding the mechanism of cutting force generation is crucial in controlling the cutting process for achieving desired

Impeller with narrow-vane is a typical thin-walled structural part of the turbine engine. The high-accuracy requirement for the impeller is difficult to achieve in the machining process due to its low structural stiffness and narrow machining domain. This paper proposes a framework for enhancing the milling accuracy of the thin-walled narrow-vane turbine impeller, which is made of NiAl-based superalloy

Additive manufacturing encompasses a set of low-cost and highly versatile tools used to prototype and fabricate three-dimensional (3D) objects with ease. In most of the additive manufacturing techniques, materials are deposited layer by layer until a 3D object is reproduced. Several additive manufacturing techniques have been developed in the previous decade, and the application of additive manufacturing

There is a continuing demand in machine tools for an increase in productivity. This can be achieved by higher speeds and process parameters, which demand structures with a high stiffness to weight ratio including the use of materials with a high specific modulus. The lack of standardized interfaces and more complex design and manufacturing process prevent the broad use of these materials. This applies

A warm stamping process of 1 and 1.2 GPa ultra-high strength steel sheets at comparatively low temperatures using rapid resistance heating was investigated to produce high strength parts. The effects of the heating temperature and rate on mechanical and surface properties of warm-stamped parts were examined. For a rapid heat rate of 100 °C/s around a heating temperature of 300 °C, the hardness of the

The effective extension of tool life while maintaining machining quality is an important research topic in advanced machining and sustainable manufacturing. Cemented carbide is widely used as the tool material in different manufacturing processes, and it has various forms and work ranges. However, the internal flaw in the tool material can induce a micro-crack which could result in the decrease of

3D grinding temperature field can be simulated by the finite difference method. When the finite difference method is used to calculate the temperature field, the boundary conditions need to be considered. Unfortunately, the difference equations for internal nodes and boundary nodes are not the same. For cuboid computing domains, there are twenty-six types of boundary nodes. This reduces the calculation

The instantaneous cutting force is the key indicator to impact surface quality of the workpiece and processing performance. In this article, from the point of view of machine tool processing system, the instantaneous vibration is decomposed into the effect of the structure of the machine tool feed system and the theoretical cutting force on the tool vibration. The instantaneous cutting forces of the

When automatically generating programs for flatbed laser cutting machines, it is advantageous to know the position of the supporting tips of the raw material. This allows the nesting layout and tool path to be adapted in an intelligent way. The problem of measuring the supporting tips of a laser cutting machine has not been considered in published literature before. We introduce possible methods first

Quality-inspection strategies play a pivotal role in providing consumers with high-quality and defect-free products. In order to withstand the competition, organizations have an increasing interest in designing quality controls that are effective in detecting defects and economically viable. Recent studies have proposed a preliminary method to evaluate inspection effectiveness and cost in low-volume

Machining composite parts is a challenging manufacturing process. Many of these composite parts are not only with very large sizes but also lack of well-defined location characteristics. And usually, these composite parts are with burrs distributed on the periphery that require trimming. An industrial robot equipped with an abrasive water jet (AWJ) has been proved to be an effective method for trimming

As an important engineering material, aluminum alloy profile is widely used in each department of national economy. With polyurethane mandrel in the hollow of the profiles, equal channel angular pressing (ECAP) can be used to refine mechanical properties of these hollow materials with good shape control effects. However, based on existing researches, the hollow profiles are only limited to circular

The main objective of the present study is to determine precisely the influence of a plunge milling cutter’s geometrical parameters on cutting forces. The plunge milling cutters studied are all indexable-insert cutters. The approach first involves modelling the specific cutting pressures for the three cutting force components. To obtain several types of cutter configurations as simply as possible,

With the increasing demand of the parts with multi-segment curvature, long length, and complex section shape, the required target shape is more and more difficult to meet. In this article, a flexible three-dimensional (3D) multi-point stretch bending processing method for a roller die is proposed, and a flexible 3D stretch bending equipment of a roller die is developed. With the application of flexible

One of the exciting applications of laser directed energy deposition (LDED) is the fabrication of complex-shaped engineering components involving graded composition. In the present work, a 2 kW fibre laser-based LDED system is used to deposit copper-nickel (CuxNi(100−x) (x = 25, 50, and 75)) layers on copper (Cu) substrate. The single tracks are deposited at different combination of laser power, scan

Microalloyed low carbon steels with high mechanical strength and elevated toughness obtained by controlled rolling have been widely used in several equipment of oil and gas industry, ensuring safety and reliability. However, residual stresses are inherent to all manufacturing processes and their knowledge is of great importance, considering that in presence of corrosive environments, the joint effect

Regenerative chatter is an annoying dynamic phenomenon in machining processes. In this paper, an adaptive sliding mode controller (SMC) is developed for turning chatter mitigation in the presence of control input constraint, parameter uncertainties, and external disturbances. Adaptive laws are employed to estimate parameter uncertainties and disturbances, while a SMC, fulfilling the control input constraint

Networking and digitization in manufacturing enable novel methods of data-driven analysis and optimization of processes through cross-process data availability. The creation of digital twins plays an important role in this. However, not all data relevant for a digital twin can be measured directly in the process. Therefore, methods are needed that enable the modelling of quantities that are difficult

Welding thick plate has become a topic of interest for multiple industrial sectors for many years. However, there are plenty of difficulties on the joining technology of medium-thickness titanium alloy plate waiting to be solved urgently. In this paper, the microstructure and residual stress distribution of 7.5-mm-thick TC4 titanium alloy jointed by laser-multi-pass-narrow-gap welding are investigated

We present a method for detecting chatter in CNC machining. Our method uses machining learning to train a classifier to determine the chatter threshold, and we use an autoencoder to reduce the dimensionality of the data. We test our method on machining audio data, and successfully detect chatter in the validation data. Our method is amenable to use on the shop floor, as a machinist using our method

The residual stresses during the cold tube drawing process affect the quality of the final tube products significantly. In this study, a new development of measurement technique that is built on the removing layer method (RLM) is developed to measure the axial and the hoop residual stresses (ARS, HRS) inside the tube wall for AISI 1010 steel. The tube is produced by the cold tube drawing process with

In order to realize the compressive stress and antifatigue manufacturing of titanium alloy TI-6Al-4V, a compound processing of longitudinal-torsional ultrasonic vibration and milling (LTUM) is proposed, a theoretical prediction model of machining-induced residual stress (RS) is established, and it is validated by experiments. The trajectory model of cutting edge in LTUM is constructed; furthermore

In recent years, significant advancements have been achieved in the domain of machine monitoring as witnessed from the beginning of the new industrial revolution (IR) known as IR 4.0. This new revolution is characterized by complete automation, and an increase in the technological deployments and advanced devices used by various systems. As a result, considerable advancement has been reported by researchers

Angle β of Fig. 2 was inaccurately displayed in the initially published version.

Abrasion machining has stood out in the current industry due to constant improvements in the dimensional accuracy of a workpiece in its finishing process. Thus, it is necessary to use cutting fluid to cool and lubricate the workpiece-wheel contact, to reduce both the high temperatures reached and the friction. However, conventional cutting fluid is harmful to the environment and poses a risk to the

The process for manufacturing automotive aluminum profiles is a multi-stage process, which includes porthole die extrusion, aging treatment, bending, and electrophoretic painting. Prediction and reduction of springback are essential in quality control of bent profiles. However, existing researches related to springback issues were mainly focused on bending process stage. This study aimed to investigate

Closed-loop inspection manufacturing (CLIM) and computer-aided inspection planning (CAIP) have increasingly been evolved into a size method that can be used to look at fashions in the industrial area with a number of methods. CAIP is hastily carried out in the gadget and will become an indispensable phase of the production system. Numerous scientific findings that tackle the theme from exclusive perspectives

Appropriate scaffolds for tissue-engineered bone not only require mechanical strength, but also conditions that promote new bone growth. Bone tissue engineering scaffolds should establish the internal pore structure of the scaffolds and promote new bone growth. Additive manufacturing technology is widely used in the field of bone tissue engineering because it can directly and accurately construct the

In vibration-assisted milling (VAM), an additional high-frequency oscillation is superimposed on the kinematics of a conventional machining process. This generates oscillations of the cutting edge in the range of a few micrometers, thereby causing a high-frequency change in the cutting speed and/or the feed. Consequently, a reduction of cutting forces, an increase of the tool life, and an improvement

This work presented an upgraded high-entropy alloy by the addition of chromium to the conventional Ti-10V-2Fe-3Al alloy to fabricate equiatomic Ti20V20Al20Fe20Cr20 high-entropy alloy via spark plasma sintering powder processing at different temperature of 700 °C, 800 °C, 900 °C, 1000 °C, and 1100 °C respectively under a constant heating rate of 100 °C /min, the pressure of 40 MPa, and holding time

Component-based software development (CBSD) is widely utilized to develop open CNC applications. It aims to build an open CNC application by composing a set of components, each implementing specific CNC sub-domain logic. Components conform to a certain component model to keep conformant interactive behaviors. Due to there is no standard granularity to decompose CNC domain and no general component model

Aiming at the flexible 3D stretch bending process (FSB) with multi-point die, the ABAQUS finite element software is used to simulate the bending process of the aluminum profile. In the FSB process, the deformation difference between the contact zone and non-contact zone of profile and roller dies is studied. By changing the pre-stretching amount of profile in the forming process, the finite element

The imitation and application of manipulability and dexterity of human arm have been investigated actively as it can improve the time efficiency and save labor cost greatly. Most of the current studies in this area only focus on recreating the structure of human arm without considering how to use the finger path for forming. In this paper, the authors present a flexible bio-inspired stretch-forming

Application of microwave energy at 2.45 GHz frequency has the potential to provide thermal energy-based alternative solution to drilling of glass in the sub-millimeter domain. In this process, the concentrated microwave energy around a concentrator (tool) is utilized to melt or ablate the target material from the workpiece. The present study discusses the effect of parameters like tool shape, tool

Aluminum alloy AA2024 has superior characteristics, including high specific strength, excellent corrosion resistance, and remarkable mechanical properties. Moreover, it has an undeniable role in the aerospace and automotive industries, which originates from its lightweight. As an advanced sheet metal in the 3D printing technology, the incremental forming process also has unique advantages in the rapid

To explore the influence of wire feed rate (WFR) to speed ratio on arc stability, interfacial microstructure and mechanical properties, cold metal transfer (CMT) weld-brazed lap joints of aluminium alloy (AA5052) to dual-phase (DP780) steel were formed at a constant optimized heat input of 80 J/mm. Cyclic representation of recorded voltage and current showed that joining process was comparatively less

This paper presents a study of the relationship between cutting force and tool crater wear of solid carbide tool during milling Ti6Al4V. The cutting force model in milling considering tool crater wear is discussed, which shows that for given the cutting conditions, tool geometries, and workpiece material, cutting force under the tool crater wear effect could be predicted easily and conveniently. The

The selection of the measurement point is one of the key steps in modelling. The traditional closed-loop control method can enhance the machine tool precision to a certain extent; however, there are some limitations in this technique. This paper presents a method that simplifies modelling a geometric error by integrating the Abbe and Bryan principles. It is found that the modelling accuracy directly