Abstract The surface modification is a pivotal step in the field of the biomedical implant in order to improve its biomedical characteristics. A number of methods can be adopted to improve surface characteristics like coating, evaporation, sputtering, and ion implantation. The surface of any material can also be improved by machining. In the present work, an electric discharge drilling (EDD) was used

Abstract Vacuum counter-pressure casting (VCPC) process is an effective forming process of producing components with complex thin-walled characteristics. In this study, a surrogate-based optimization method with five process parameters is used to reduce the shrinkage porosity defect during the VCPC process of a complicated thin-walled aluminum alloy casing. The prediction of the shrinkage porosity

Abstract Fibre metal laminates (FMLs) are multilayered metal composite materials currently used in aeronautical structures, especially where fatigue and impact resistance are required. FMLs are produced in large panels and often require assembly using the drilling process for riveting purposes. Hole making is a critical machining process in the joining and assembly of aeronautical components, which

Abstract In robotic polishing applications, the rotating polisher will generate strong vibration disturbance, which makes it more difficult to detect and control the contact force. This paper proposes a novel and practical method to detect and control the contact force using the built-in sensors (motor encoders and joint torque sensors) for actual robotic polishing in harsh conditions of strong vibration

Abstract The longitudinal-torsional mode horn has gained popularity recently for ultrasonic welding (USW) because it is more efficient than a conventional longitudinal horn. Addition of slanting grooves to the front mass to achieve torsionality is not a novel approach, and few works have already addressed this issue, but comparative studies about the effect of different groove parameters such as length

Abstract Blisk of aerospace engine is one of the sophisticated key parts in the aviation, which is difficult to machine considering its structural and material properties. The present paper develops a five-axis CNC milling machine for fabricating blisk with high-efficiency and high-quality as well as ensuring this milling machine with high precision and precision retention. Therefore, a precision analysis

Abstract In abrasive waterjet (AWJ) process, abrasive properties are of critical factors that influence machining performances. Abrasive process parameters including abrasive material, size and flow rate, exert a significant impact on cutting ability and quality of AWJ. In this paper, monolithic abrasive material (garnet, alumina and silicon carbide) and corresponding mixing abrasive materials are

Abstract The modeling of equivalent fixture error (EFE) in machining process has been proved to be an effective way for variation reduction. However, previously developed approaches did not describe the EFE phenomenon of workpiece deformation. This paper proposes a comprehensive EFE model that can simultaneously transform the datum errors, machine tool path error and workpiece deformation to EFE. The

Abstract As an advanced additive manufacturing technology, laser cladding has become a research hotspot in the fields of rapid manufacturing and surface modification in recent years. The quality of the cladding layer directly depends on the choice of process parameters. In order to obtain high quality cladding layer, the effects of laser power, scanning speed, and powder feeding rate on the quality

Abstract The continuous direct extrusion is an economic and efficient process to manufacture high-quality aluminium profiles. However, because of multiple billets processing, transient defects (coring and charge welds) can be generated affecting portions of the profiles and deteriorating their mechanical properties. In case of structural applications, the reliable prediction of the onset and extend

Abstract The presented article is focused on the evaluation of mechanical properties of stainless steel disintegrated using an ultrasonically modulated pulsating water jet. The experimental procedure was performed using a nozzle with a circular orifice with an equivalent diameter of 1.6 mm. The mechanical properties evaluation was based on indentation elasticity modulus Ep and nano hardness H, which

Abstract High-power lasers are very effective in welding of plates thicker than 10 mm due to the keyhole mode. High-power intensity generates a vapor-filled cavity which provides substantial penetration depth. Due to the narrow and deep weld geometry, there is susceptibility to high hardness and weld defects. Imperfections occur due to keyhole instability. A 16-kW disk laser was used for single-pass

Abstract With the development of aerospace, military, medical, and 3C industries, the design of aspherical optical component has attracted more and more attention. As a substitute for the traditional manufacturing process for glass materials, the glass molding process (GMP) has the advantages of high forming accuracy, short production cycle, low cost, and non-pollution. This paper presents an overview

Abstract Reverse micro-EDM (RMEDM), a contactless electro-thermal micro-machining process, is extensively used for generating array of similar aspect ratio of protruded micro-features. The drawback of this process is the formation of recast layer on the fabricated surface that has different mechanical and chemical properties as compared with the base material. Usually, destructive characterization

Abstract Machining-induced residual stress plays a significant role in the corrosion resistance and fatigue life of the manufacturing end product. In the current study, milling experiments were performed to investigate the influence of pre-stress on the surface residual stresses. For this purpose, finite element (FE) simulations of the orthogonal cutting based on arbitrary Lagrangian-Eulerian approach

Abstract In manufacturing of femoral head prostheses, the roundness of the femoral head is important. In order to reduce out-of-roundness when machining with a conventional CNC machine, a compensation technique with a fast tool servo was developed. The fast tool servo with piezoelectric actuator was fabricated and installed on a conventional CNC machine, and a compensation technique was implemented

Abstract Under the influence of a high-speed, interrupted-cutting impact load, the damage degree quickly increases following any structural damage in a milling cutter. The presence of structural damage must be explored given the fact that these conditions may result in irreparable and serious accidents if not immediately detected. Milling cutter damage has multi-scale characteristics. Therefore, the

Abstract Material shrinkage commonly occurs in additive manufacturing and compromises the fabrication quality by causing unwanted distortions or residual stresses in fabricated parts. Even though it is known that the resulting deformations and stresses are highly dependent on the writing trajectory, no effective strategy for choosing suitable trajectories has been reported to date. Here, we present

Abstract Quality function deployment (QFD) is a method commonly used in manufacturing industries to identify customer requirements (CRs) and the manufacturing capacity to meet CRs. Importance rate (IR) of CRs plays an important role in the QFD method. The existing methods in determining IR of CRs cannot consider all related factors of customer satisfaction, need importance, personal information, and

Abstract The presence of defects in a powder bed fusion (PBF) process can lead to the formation of flaws in consolidated parts. Powder bed defects (PBDs) have different sizes and shapes and occur in different locations in the built area. Those variations pose great challenges to their detection. In this study, a deep convolution neural network was applied to detect three typical types of PBDs in a

Abstract This work aimed at introducing and exploring the potential of a thermal management technique, named as near-immersion active cooling (NIAC), to mitigate heat accumulation in Wire + Arc Additive Manufacturing (WAAM). According to this technique concept, the preform is deposited inside a work tank that is filled with water, whose level rises while the metal layers are deposited. For validation

Abstract Recently, there has been a significant amount of interest in additive manufacturing of aerospace parts from heat-resistant alloys due to the ability of producing more complex shapes parts in comparison with conventional technologies. This paper describes the research results of selective laser melting (SLM) of nickel-based IN-738 superalloy powder. The main research results of studies are

Abstract Controlling the profile and edge drop in the cold rolling process is crucial especially in applications involving silicon steel. In non-oriented silicon steel production, the work rolls shifting control is widely applied in 6-high tandem cold mills and the differences of the control characters of different stands have been gradually recognized. However, because of the lack of research on shifting

Abstract Grinding tools with superabrasive grains can be manufactured from different bond materials. In several industrial applications, metallic bond systems are used. In general, these show good grain retention and offer a high thermal conductivity, when compared to the other widely used bond types such as vitrified and resin bonds. One drawback of the metallic bond is the lack of pores in the grinding

Abstract Welding is widely used for joining steel components in the automobile industry. With the use of high-quality materials, welding defects began to become increasingly complex. Immobilized oxide is one of the recent complex defects. Immobilized oxide defects generated in gas metal arc welding (GMAW) of high-strength steel and high-strength galvanized steel result in unpainted part on the surface

Abstract In situ ceramic phase reinforced Ti-based composite coatings were successfully fabricated on Ti-6Al-4V alloys by laser cladding using Ti + Al + Si mixed powders with different NbC contents (0, 5, 10, 15 wt.%). The effects of different NbC content on the microstructural evolution, hardness, and wear behaviors of the Ti-based composite coatings were studied. The results showed that the phase

Abstract Demand in clean alternative energy source together with fuel cells developments has attracted researchers towards utilization of hydrogen (H2). Common production of hydrogen from fossil fuels requires further pretreatment prior to the application, which makes separation and purification technology a very crucial component. Membrane reactors for water-gas shift reaction which was used for H2

Abstract Various approaches have been attempted by researchers to break through the limitation of axisymmetric shape in metal spinning. In this study, a synchronous multipass spinning method for offset blanks is proposed. The motion of the roller and the rotation of the mandrel are synchronized to achieve asymmetric shapes. The roller trajectory is represented by a set of scattered data which contains

Abstract The thickness distribution of thermoformed products is greatly affected by the viscoelastic behavior of the extruded polymer sheet. In this work, linear and nonlinear rheological experiments are carried out to characterize the viscoelastic properties of acrylonitrile-butadiene-styrene sheets under thermoforming conditions including a wide range of temperatures, strains, and strain rates. First

Abstract Abrasive flow machining (AFM) is a non-traditional finishing process by using the semi-solid abrasive media as a finishing tool, and usually applied to finish fine, complex components in manufacturing industries. In AFM process, the final surface quality and finishing efficiency are crucial finishing properties which have drawn wide attention and are always affected by initial surface texture

In the accepted paper, the authors’ affiliation has been wrongly typeset as People’s Republic of China, but this should read Taiwan. The correct affiliations are shown below.

Abstract Underwater laser machining process is an alternative method to cut materials with less thermal damage due to the water cooling of workpiece during the ablation. However, the rapid cooling induced by water can instantly solidify the laser-molten material rather than expel it to form a cut. To understand the roles of processing temperature on ablation performance in water, this paper presents

Abstract In addition to having significant effects on the service life of machined parts, residual stress can cause large deformations during machining of thin-walled parts in aerospace field. The residual stress in machined part surface layer is induced by mechanical and thermal stress in the machining process of parts. Therefore, it is essential to accurately predict the generated residual stress

Abstract Carbon fiber-reinforced plastic (CFRP) is used widely in many industries. During drilling CFRP, exit drill-induced defects such as burrs and delamination are easy to occur. In the existing model, the crack zone is assumed as a circle or an ellipse, and concrete forming process of the delamination and the burrs does not be truly involved. In this study, the formation mechanisms of the delamination

Abstract In this competitive world, industries are looking for smart technologies to compete; these technologies help R&D people to explicit the ideas and bring the product to the market at shorter lead times and with affordable cost. Each AM machine has its own unique capabilities in manufacturing a product, utilising materials, material intake and wastages. Machine and material costs are the significant

Abstract Fixtures are used to locate and secure workpieces for further machining or measurement process. Design of these fixtures remains a costly process due to the significant technical know-how required. Automated fixture design can mitigate much of these costs by reducing the dependence on skilled labour, making it an attractive endeavour. Historical attempts in achieving automated fixture design

Abstract Collaborative robotics have a large potential for use in industrial applications. Nevertheless, this potential is currently unrealized and one of the reasons is the challenges in planning and designing while considering the safety requirements of these new types of applications. In this article, we will use an exemplary application to describe the many design decisions that are made during

Abstract It is of great economic benefit to realize the automatic welding of 90° welds, and difficulty of automatic welding of 90° welds is the machine identification of the corner points of 90° welds. The math model of welding-torch pose was built, and the identification algorithms of wire extension, welding deviations, and tilt angles of welding torch have been studied respectively. In this paper

Abstract Geometric error measurement is crucial for error compensation and machining accuracy of CNC machine tools. However, traditional double-ball bar (DBB) method cannot be used for full-scale measurement of geometric errors due to the constant length of bars. In this paper, a full-scale measurement of geometric errors for CNC machine tools with high efficiency is carried out based on the double

Abstract The finite element method (FEM) has considerably contributed to the development of advanced manufacturing methods for metal structures. The prediction of the final shape of a component is of great interest to the manufacturing industry. The level of demand may increase due to multistage processes. Therefore, including all steps of the manufacturing chain in the simulations is a key to being

Abstract This work presents an optical inspection-guiding system for electronic board manufacturing. The system monitors in real time the mounting process of electronic components performed by an operator. It visually guides the operator through the mounting process while checking the correctness of its actions. As a consequence, mounting errors are reduced while operator comfort is enhanced. This

Abstract Laser peening has an extensive application in traditional manufacturing industry. However, in additive manufacturing, the initial stresses on the parts often reduce the effects of laser peening and make it hard to achieve a desirable residual stress distribution. In this investigation, the interaction of initial residual stress and laser peening-induced stress was studied through numerical

Abstract CNC machine tools play an extremely important role in the equipment manufacturing industry. Because a machine tool has multiple geometric errors which are highly coupled, the error identification process is difficult. Most direct and indirect measurement methods do not consider the dynamic errors in the actual cutting process. This study aims to optimize the error identification process of

Abstract Because of the elastic deformation of rolling mills in rolling, the edge drop in thickness of rolled ultra-high strength steel sheet was remarkable, thus the thickness distribution was not uniform. The distribution of angle before and after unloading in V-bending of the ultra-high strength steel sheets having such a thickness distribution was measured. The bend angle was nonuniformly distributed

Establishing how to effectively manufacture cell therapies is an industry-level problem. Decentralised manufacturing is of increasing importance, and its challenges are recognised by healthcare regulators with deviations and comparability issues receiving specific attention from them. This paper is the first to report the deviations and other risks encountered when implementing the expansion of human

The monitoring of rotating machinery condition has been a critical component of the Industry 4.0 revolution in enhancing machine reliability and facilitating intelligent manufacturing. The introduction of condition-based monitoring has effectively reduced the catastrophic events and maintenance cost across various industries. One of the major challenges of the diagnosis remains as majority of the diagnostic

The successful prediction of the remaining useful life of rolling element bearings depends on the capability of early fault detection. A critical step in fault diagnosis is to use the correct signal processing techniques to extract the fault signal. This paper proposes a newly developed diagnostic model using a sparse-based empirical wavelet transform (EWT) to enhance the fault signal to noise ratio

One of the most common parts to maintain system balance and support the various load in rotating machinery is the rolling element bearing. The breakdown of the element in bearings leads to inefficiency and sometimes catastrophic events across various industries. The main challenge over the last few years for fault diagnosis of bearings is the early detection of fault signature. In this paper, an adaptive

Manufacturing environments face many unique challenges in regards to balancing high standards of both product quality and production efficiency. Proper diagnostic health assessment is essential for maximizing uptime and maintaining product and process quality. Information for diagnostic assessments, and reliability information in general, can come from a myriad of sources that can be processed and

A fourth industrial revolution, occurring in global manufacturing, provides a vision of future manufacturing systems that incorporate highly dynamic physical systems, robust and responsive communications systems, and computing paradigms to maximize efficiency, enable mobility, and realize the promises of the digital factory. Wireless technology is a key enabler of that vision. A comprehensive graphical

There are three primary aspects to the economics of additive manufacturing: measuring the value of goods produced, measuring the costs and benefits of using the technology, and estimating the adoption and diffusion of the technology. This paper provides an updated estimate of the value of goods produced. It then reviews the literature on additive manufacturing costs and identifies those instances in

In this paper, we propose an architectural design and software framework for fast development of descriptive, diagnostic, predictive, and prescriptive analytics solutions for dynamic production processes. The proposed architecture and framework will support the storage of modular, extensible, and reusable Knowledge Base (KB) of process performance models. The approach requires developing automated