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The investigation aims to improve Nd: YAG laser technology for precision cutting of carbon fiber reinforcing polymers (CFRPs), specifically those containing newly created resin (NDR) from the polyethylene and polyurea group, is the goal of the study. The focus is on showing how Nd: YAG lasers may be used to precisely cut CFRP with NDR materials, emphasizing how useful they are for creating intricate and long-lasting components.

The study employs a systematic approach that includes complicated factorial designs, Taguchi L27 orthogonal array trials, Gray relational analysis (GRA) and machine learning predictions. The effects of laser cutting factors on CFRP with NDR geometry are investigated experimentally, with the goal of optimizing the cutting process for greater quality and efficiency. The approach employs data-driven decision-making with GRA, which improves cut quality and manufacturing efficiency while producing high-quality CFRP composites. Integration of machine learning models into the optimization process significantly boosts the precision and cost-effectiveness of laser cutting operations for CFRP materials.

The work uses Taguchi L27 orthogonal array trials for systematically explore the effects of specified parameters on CFRP cutting. The cutting process is then optimized using GRA, which identifies influential elements and determines the ideal parameter combination. In this paper, initially machining parameters are established at level L3P3C3A2, and the optimal machining parameters are determined to be at levels L3P2C3A3 and L3P2C1A2, based on predictions and experimental results. Furthermore, the study uses machine learning prediction models to continuously update and optimize kerf parameters, resulting in high-quality cuts at a lower cost. Overall, the study presents a holistic method to optimize CFRP cutting processes employing sophisticated techniques such as GRA and machine learning, resulting in better quality and efficiency in manufacturing operations.

The novel concept is in precisely measuring the kerf width and deviation in CFRP samples of NDR using sophisticated imaging techniques like SEM, which improves analysis and precision. The newly produced resin from the polyethylene and polyurea group with carbon fiber offers a more precise and comprehensive understanding of the material's behavior under different cutting settings, which makes it novel for kerf width and kerf deviation in their studies. To optimize laser cutting settings in real time while considering laser machining conditions, the study incorporates material insights into machine learning models.

This paper aims to present spot pattern welding (SPW) as a scanning strategy for laser-foil-printing (LFP) additive manufacturing (AM) in place of the previously used continuous pattern welding (CPW) (line-raster scanning). The SPW strategy involves generating a sequence of overlapping spot welds on the metal foil, allowing the laser to form dense and uniform weld beads. This in turn reduces thermal gradients, promotes material consolidation and helps mitigate process-related risks such as thermal cracking, porosity, keyholing and Marangoni effects.

304L stainless steel (SS) feedstock is used to fabricate test specimens using the LFP system. Imaging techniques are used to examine the melt pool dimensions and layer bonding. In addition, the parts are evaluated for residual stresses, mechanical strength and grain size.

Compared to CPW, SPW provides a more reliable heating/cooling relationship that is less dependent on part geometry. The overlapping spot welds distribute heat more evenly, minimizing the risk of elevated temperatures during the AM process. In addition, the resulting dense and uniform weld beads contribute to lower residual stresses in the printed part.

To the best of the authors’ knowledge, this is the first study to thoroughly investigate SPW as a scanning strategy using the LFP process. In general, SPW presents a promising strategy for securing embedded sensors into LFP parts while minimizing residual stresses.

Integrating additive manufacturing (AM) tools in traditional mold-making provides complex yet affordable sand molds and cores. AM processes such as selective laser sintering (SLS) and Binder jetting three-dimensional printing (BJ3DP) are widely used for patternless sand mold and core production. This study aims to perform an in-depth literature review to understand the current status, determine research gaps and propose future research directions. In addition, obtain valuable insights into authors, organizations, countries, keywords, documents, sources and cited references, sources and authors.

This study followed the systematic literature review (SLR) to gather relevant rapid sand casting (RSC) documents via Scopus, Web of Science and EBSCO databases. Furthermore, bibliometrics was performed via the Visualization of Similarities (VOSviewer) software.

An evaluation of 116 documents focused primarily on commercial AM setups and process optimization of the SLS. Process optimization studies the effects of AM processes, their input parameters, scanning approaches, sand types and the integration of computer-aided design in AM on the properties of sample. The authors performed detailed bibliometrics of 80 out of 120 documents via VOSviewer software.

This review focuses primarily on the SLS AM process.

A SLR and bibliometrics using VOSviewer software for patternless sand mold and core production via the AM process.

Performing accurate numerical simulations of electrical drives, the precise knowledge of the local magnetic material properties is of utmost importance. Due to the various manufacturing steps, e.g. heat treatment or cutting techniques, the magnetic material properties can strongly vary locally, and the assumption of homogenized global material parameters is no longer feasible. This paper aims to present the general methodology and two different solution strategies for determining the local magnetic material properties using reference and simulation data.

The general methodology combines methods based on measurement, numerical simulation and solving an inverse problem. Therefore, a sensor-actuator system is used to characterize electrical steel sheets locally. Based on the measurement data and results from the finite element simulation, the inverse problem is solved with two different solution strategies. The first one is a quasi Newton method (QNM) using Broyden's update formula to approximate the Jacobian and the second is an adjoint method. For comparison of both methods regarding convergence and efficiency, an artificial example with a linear material model is considered.

The QNM and the adjoint method show similar convergence behavior for two different cutting-edge effects. Furthermore, considering a priori information improved the convergence rate. However, no impact on the stability and the remaining error is observed.

The presented methodology enables a fast and simple determination of the local magnetic material properties of electrical steel sheets without the need for a large number of samples or special preparation procedures.

Liquid-assisted laser surface texturing technology was used to create composite microtextures on triangular guide rail surfaces to enhance their tribological properties.

Numerical simulations were used to investigate the impact of various microtextures on fluid dynamic lubrication. Reciprocating friction and wear tests, followed by mechanistic analysis, examined the combined tribological effects of microtextured surfaces and lubricants.

The numerical simulation outcomes reveal a significant augmentation in the influence of fluid dynamic pressure due to composite microtextures, consequently amplifying the load-bearing capacity of the oil film. The average friction coefficient of composite microtextured samples was approximately 0.136 in reciprocating pin-on-disk friction tests, representing approximately 17% decrease compared to polished samples. Triangular guide rails with composite microtextures demonstrated the lowest average coefficient under conditions of high-speed and heavy-loading in the reciprocating friction and wear tests. Additionally, the presence of composite microtextures was found to promote the formation of adsorbed and friction films during friction, potentially contributing to the enhancement of tribological properties.

Triangular guide rails face high friction and wear, limiting their stability in demanding applications like machine tool guideways. This paper proposes a novel approach for steel triangular guide rails, involving composite microtexturing, numerical fluid simulations, liquid-assisted laser surface texturing and friction-wear testing. By implementing composite microtextures, the method aims to reduce friction coefficients and extend guideway service life, thereby saving energy and reducing maintenance costs. Enhancing the antifriction and antiwear properties of machine tool guideways is crucial for improving performance and longevity.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0183/

This study aims to establish a robust evaluation framework for suppliers within the automotive supply chain, specifically in the stamping sector. The primary objectives are to elucidate the performance criteria of suppliers, identify indicators and scales for measuring these criteria and find the importance of the criteria.

The evaluation framework comprises a criteria hierarchy and indicators developed based on the evaluation criteria of major automotive manufacturers. Specific indicators and measurement scales are recommended for assessing suppliers. Importance weights for the criteria are assigned based on the input of nine experts using the Analytic Hierarchy Process (AHP). Finally, four sheet metal stamping tooling (SMST) suppliers are evaluated by four specialists using the proposed evaluation framework.

The study introduces a novel classification of criteria, encompassing financial and commercial perspectives, delivery capability, supplier facility and cultural approaches and business process necessities. The findings underscore the significance of financial and commercial stability in the selection of SMST suppliers, emphasizing their role in mitigating risks associated with disruptions, bankruptcies and unforeseen events. Additionally, several SMST evaluation factors identified in this study contribute to the development of resilience capabilities, highlighting the crucial importance of their inclusion and assessment in the proposed evaluation framework.

This research presents a comprehensive model for evaluating SMST suppliers, which tackles the multidisciplinary challenges within the automotive supply chain. Given the inadequacy or nonexistence of current SMTS selection models, this study bridges the gap by exploring potential and necessary criteria, alongside 116 specific indicators and measurement scales.

The investigation concentrated on studying a distinct category of tubular heat exchanger that uses swirling airflow over tube bundle maintained at constant heat flux. Swirl flow is achieved using a novel perforated baffle plate with rectangular openings and multiple adjustable opposite-oriented saw-tooth flow deflectors. These deflectors were strategically placed at the inlet of the heat exchanger to create a swirling flow downstream.

The custom-built axial flow heat exchanger consists of three baffle plates arranged longitudinally supporting tube bundle maintained at constant heat flux. The baffle plate equipped with saw-tooth flow deflector of various geometry represented by space height ratio(e/h). Next, ambient air was then directed over the tube bundle at varying Reynolds number and the effect of baffle spacing (PR), Space height ratio (e/h) and inclination angle(a) of deflectors on performance of heat exchanger was experimentally analyzed.

The heat transfer augmentation of heat exchanger for given operating condition is strongly dependent on geometry, inclination angle of deflector and baffle spacing.

An average improvement of 1.42 times in thermal enhancement factor was observed with inclination angle of 30°, space height ratio of 0.4 and a pitch ratio of 1.2 when compared to a heat exchanger without a baffle plate under similar operating conditions.

This paper aims to analyze the influence of welding-induced mechanical stress of a magnetic core material on the performance behavior of a permanent magnet excited synchronous machine (PMSM). Welding, interlocking, clinching and the use of adhesives are state-of-the-art packaging technologies used in the manufacturing of electrical machines. However, the packaging processes degrade the electromagnetic properties of the electric steel sheets, thereby decreasing the performance and achievable range of the electric vehicle.

In this paper, an approach that maps the local changes in magnetic properties due to welding induced stress with the stress values is developed. The welding process induces internal stress inside the steel sheet due to the diffusion of thermal energy into the sheets. Other effects are the changes in the micro structures of the steel sheets (grain sizes). These induced mechanical stresses lead to significant deterioration of the electromagnetic properties. They also lead to an increase in iron loss attributed to steel lamination.

A low speed (city), a high-speed (highway) and WLTC-c3 driving cycle will be used to analyze the effects of the induced stresses on the machine efficiency at the different operating conditions. A high-speed PMSM with a maximum speed of 26,000 min⁻¹ and maximum torque of 130 Nm is designed for this study.

The value of this study is in the development of a local varying modeling approach that analyses the influence of weld-induced stress on the performance of electrical machines. Its originality is evident in the mapping methodology. This will enable an application dependent improvement possibilities due to the understanding of the impact of weld-induced stress on the electromagnetic properties of weld-packaged core.

An investigation was conducted into the impact of various process parameters on the surface and subsurface quality of glass-ceramic materials, as well as the mechanism of material removal and crack formation, through the use of ultrasonic-assisted grinding.

A mathematical model of crack propagation in ultrasonic-assisted grinding was established, and the mechanism of crack formation was described through the model. A series of simulations and experiments were conducted to investigate the impact of process parameters on crack depth, surface roughness, and surface topography during ultrasonic-assisted surface and axial grinding. Additionally, the mechanism of crack formation was explored.

During ultrasonic-assisted grinding, the average grinding forces are between 0.4–1.0 N, which is much smaller than that of ordinary grinding (1.0–3.5 N). In surface grinding, the maximum surface stresses between the workpiece and the tool gradually decrease with the tool speed. The surface stresses of the workpiece increase with the grinding depth, and the depth of subsurface cracks increases with the grinding depth. With the increase of the axial grinding speed, the subsurface damage depth increases. The roughness increases from 0.780um/1.433um.

A mathematical model of crack propagation in ultrasonic-assisted grinding was established, and the mechanism of crack formation was described through the model. The deformation involved in the grinding process is large, and the FEM-SPH modeling method is used to solve the problem that the results of the traditional finite element method are not convergent and the calculation efficiency is low.

This paper aims to introduce a wheeled vehicle robot for adapting to the surface terrain of the 500-m diameter reflector of the FAST radio telescope in China.

By analyzing vehicles applied for different off-road environments, a six-wheeled architecture with a passive “triple-bogie” suspension is selected. A subscale model of the vehicle robot is designed, along with statics modeling and multibody simulations of the dynamics on simulated reflector panel surfaces. The slope- and step-climbing abilities of the subscale vehicle are discussed in accordance with numerical and experimental tests. An engineering scale vehicle is subsequently manufactured and tested on surface terrains of lateral as well as vertical gaps, and is finally validated on the FAST reflector.

This model of vehicle robot exhibits strong structure stability under desired payload. It can stably cross lateral gaps for maximum surface slope 28° and can traverse vertical gap for maximum surface slope 23°. The traversing abilities satisfy the mobility requirements subjected to surface terrains of FAST reflector.

The engineering vehicle robot negotiates the lateral as well as vertical gaps between triangle panels and has been successfully applied to the FAST reflector serving for inspection and maintenance work.