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The purpose of this study is to produce a low-cost sheet metal forming mold made from the low melting point Bi58Sn42 (bismuth) alloy by using an open-source desktop-type material extrusion additive manufacturing system and to evaluate the performance of the additively manufactured mold for low volume sheet metal forming. Thus, it was aimed to develop a fast and inexpensive die tooling methodology for low-volume batch production.

Initially, the three-dimensional printing experiments were performed to produce the sheet metal forming mold. The encountered problems during the performed three-dimensional printing experiments were analyzed. Accordingly, both tunings in process parameters (extrusion temperature, extrusion multiplier, printing speed, infill percentage, etc.) and customizations on the extruder head of the available material extrusion additive manufacturing system were made to print the Bi58Sn42 alloy properly. Subsequently, the performance of the additively manufactured mold was evaluated according to the dimensional change that occurred on it during the performed pressing operations.

Results showed that the additively manufactured mold was rigid enough and proved to have sufficient strength in sheet metal forming operations for low-volume production.

Alternative mold production was carried out using open-source material extrusion system for low volume sheet metal part production. Thus, cost effective solution was presented for agile manufacturing.

This study aims to develop a novel thermal modeling strategy to simulate electron beam powder bed fusion at part scale with machine-varying process parameters strategy. Single-bead and part-scale experiments and modeling were studied. Scanning strategies were described by the process controlling functions that enabled modeling.

The finite element analysis thermal model was used along with the powder bed fusion with electron beam experiments. The proposed strategy involves dividing a part into smaller sections and creating meso-scale models for each subsection. These meso-scale models take into consideration the variable process parameters, including power and velocity of the moving heat source, during part building. Subsequently, these models are integrated to perform partscale simulations, enabling more realistic predictions of thermal accumulation and resulting distortions. The model was built and validated with single-bead experiments and bulky parts with different features.

Single-bead experiments demonstrated an average error rate of 6%–24% for melt pool dimension prediction using the proposed meso-scale models with different scanning control functions. Part-scale simulations for three different geometries (cantilever beams with supports, bulk artifact and topology-optimized transfer arm) showed good agreement between modeled temperature changes and experimental deformation values.

This study presents a novel approach for electron beam powder bed fusion modeling that leverages meso-scale models to capture the influence of variable process parameters on part quality. This strategy offers improved accuracy for predicting part geometry and identifying potential defects, leading to a more efficient additive manufacturing process.

Bionic flapping-wing aerial vehicles (FWAVs) mimic natural flyers to generate the lift and thrust, such as birds, bats and insects. As an important component of the FWAVs, the flapping wings are crucial for the flight performance. The aim of this paper is to study the effects of different wings on aerodynamic performance.

Inspired by the wings structure of birds, the authors design four cambered wings to analyze the effect of airfoils on the FWAVs aerodynamic performance. The authors design the motor-driven mechanism of flapping wings, and realize the control of flapping frequency. Combined with the wind tunnel equipment, the authors build the FWAVs force test platform to test the static and dynamic aerodynamic performance of different flapping wings under the state variables of flapping frequency, wind speed and inclined angle.

The results show that the aerodynamic performance of flapping wing with a camber of 20 mm is the best. Compared with flat wing, the average lift can be improved by 59.5%.

Different from the traditional flat wing design of FWAVs, different cambered flapping wings are given in this paper. The influence of airfoils on aerodynamic performance of FWAVs is analyzed and the optimal flapping wing is obtained.

The paper focuses on the issue of manual rebar-binding tasks in the construction industry, which are marked by high labor intensity, high costs and inefficient operations. The rebar-binding robots that are currently available are not fully mature. Most of them can only bind one or two nodes in one position, which leads to significant time wastage in movement. Based on a new type of rebar-binding robot, this paper aims to propose a new movement and binding control that reduces manpower and enhances efficiency.

The robot is combined with photoelectric sensors, travel switches and other sensors. It is supposed to move accurately and run in a limited area on the rebar mesh through logical judgment, speed control and position control. Machine vision is used by the robot to locate the rebar nodes and then adjusts the binding-gun position to ensure that multiple rebar nodes are bound sequentially.

By moving on the rebar mesh with accuracy, the robot meets the positioning accuracy requirements of the binding module, with experimental testing accuracy within 5 mm. Furthermore, its ability to bind four rebar nodes in one place results in a high efficiency and a binding effect that meets building standards.

The innovative design of the robot can adapt itself to the rebar mesh, move accurately to the target position and bind four nodes at that position, which reduces the number of movements on the mesh. Repetitive and heavy rebar-binding tasks can be efficiently completed by the robot, which saves human resources, reduces worker labor intensity and reduces construction overhead. It provides a more feasible and practical solution for using robots to bind rebar nodes.

This study aims to address the issue of random movement and non coordination between docking mechanisms and locking mechanisms, and proposes a comprehensive dynamic docking control architecture that integrates perception, planning, and motion control.

Firstly, the proposed dynamic docking control architecture uses laser sensors and a charge-coupled device camera to perceive the pose of the target. The sensor data are mapped to a high-dimensional potential field space and fused to reduce interference caused by detection noise. Next, a new potential function based on multi-dimensional space is developed for docking path planning, which enables the docking mechanism based on Stewart platform to rapidly converge to the target axis of the locking mechanism, which improves the adaptability and terminal docking accuracy of the docking state. Finally, to achieve precise tracking and flexible docking in the final stage, the system combines a self-impedance controller and an impedance control algorithm based on the planned trajectory.

Extensive simulations and experiments have been conducted to validate the effectiveness of the dynamic docking system and its control architecture. The results indicate that even if the target moves randomly, the system can successfully achieve accurate, stable and flexible dynamic docking.

This research can provide technical guidance and reference for docking task of unmanned vehicles under the ground conditions. It can also provide ideas for space docking missions, such as space simulator docking.

This study aims to tackle control challenges in soft robots by proposing a visually-guided reinforcement learning approach. Precise tip trajectory tracking is achieved for a soft arm manipulator.

A closed-loop control strategy uses deep learning-powered perception and model-free reinforcement learning. Visual feedback detects the arm’s tip while efficient policy search is conducted via interactive sample collection.

Physical experiments demonstrate a soft arm successfully transporting objects by learning coordinated actuation policies guided by visual observations, without analytical models.

Constraints potentially include simulator gaps and dynamical variations. Future work will focus on enhancing adaptation capabilities.

By eliminating assumptions on precise analytical models or instrumentation requirements, the proposed data-driven framework offers a practical solution for real-world control challenges in soft systems.

This research provides an effective methodology integrating robust machine perception and learning for intelligent autonomous control of soft robots with complex morphologies.

This paper aims to address the safety concerns of path-planning algorithms in dynamic obstacle warehouse environments. It proposes a method that uses improved artificial potential fields (IAPF) as expert knowledge for an improved deep deterministic policy gradient (IDDPG) and designs a hierarchical strategy for robots through obstacle detection methods.

The IAPF algorithm is used as the expert experience of reinforcement learning (RL) to reduce the useless exploration in the early stage of RL training. A strategy-switching mechanism is introduced during training to adapt to various scenarios and overcome challenges related to sparse rewards. Sensor inputs, including light detection and ranging data, are integrated to detect obstacles around waypoints, guiding the robot toward the target point.

Simulation experiments demonstrate that the integrated use of IDDPG and the IAPF method significantly enhances the safety and training efficiency of path planning for mobile robots.

This method enhances safety by applying safety domain judgment rules to improve APF’s security and designing an obstacle detection method for better danger anticipation. It also boosts training efficiency through using IAPF as expert experience for DDPG and the classification storage and sampling design for the RL experience pool. Additionally, adjustments to the actor network’s update frequency expedite convergence.

The purpose of this paper is to determine the effect of clothing fabrics, sizes and air ventilation rate on the volume and thickness of the air gap under the air ventilation garments (AVGs).

The geometric models of the human body and clothing were obtained by using a 3D body scanner. Then the distribution of the volume and thickness of the air gap for four clothing fabrics and three air ventilation rates (0L/S, 12L/S and 20L/S) were calculated by Geomagic software. Finally, a more suitable fabric was selected from the analysis to compare the distribution of the air gap entrapped for four clothing sizes (S, M, L and XL) and the three air ventilation rates.

The results show that the influence of air ventilation rate on the air gap volume and thickness is more obvious than that of the clothing fabrics and sizes. The higher is the air ventilation rate, the thicker is the air gap entrapped, and more evenly distributed is the air gap. It can be seen that the thickness of the air gap in the chest does not change significantly with the changes of the air ventilation rates, clothing fabrics and sizes, while the air gap in the waist is affected significantly.

This research provides a better understanding of the distribution of the air gap entrapped in ventilated garments, which can help in designing the optimal air gap dimensions and thus provide a basis and a reference for the design of the AVGs.

This paper aims to select an appropriate contact force model and apply it to the interaction model between the balls and the cage in the rolling bearings to describe the elastic–plastic collision phenomena between the two.

Taking the ball–disk collision mode as an example, several main contact force models were compared and analyzed through simulation and experiment. In addition, based on the consideration of yield strength of materials and initial collision velocity, a variable recovery coefficient model was proposed, and its validity and accuracy were verified by the ball–disk collision experiments. Then, respectively, the Flores model and the Hertz model were applied to the interaction between the balls and the cage, and the dynamics simulation results were compared.

The results indicate that the Flores model has good regression of recovery coefficient, indicating good applicability for both elastic and elastic–plastic contacts and can be applied to the contact collision situations of various materials. Under certain working conditions, there are significant differences in the dynamics results of rolling bearings simulated using the Flores model and Hertz model, respectively.

This paper applies the Flores model with variable recovery coefficients to the dynamics simulation analysis of ball bearings to solve the elastic–plastic collision problem between the rolling elements and the cage that cannot be reasonably handled by the Hertz model.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-04-2024-0138/