Journal of Manufacturing and Materials Processing

Additive manufacturing (AM) has moved beyond prototyping and now produces functional, load-bearing components [...]

The present research investigates the optimization of ball burnishing (BB) process parameters to create regular lubricating grooves on multilayer connecting rod liners to prevent engine seizure. The study utilized a Taguchi L9 fractional orthogonal array to evaluate the impact of ball diameter, deforming force, and feed rate on the resulting groove widths. Statistical analysis (ANOVA) revealed th…

Small-scale clay-brick yards require molding equipment that increases output while remaining mobile, locally serviceable, and compatible with intermittent material supply. This article documents the functional architecture and exploratory operational performance of the mobile 12-cavity hydraulic clay-brick molding machine (ML12). Its design contribution is the integration of a dimensioned wheeled…

Optical surface deviations in ophthalmic optics arise from fast tool servo errors, the tool footprint, freeform surface residuals, and the freeform surface curvature responses across processing stages. In this paper, a PAM-Net physics–AI dual-driven compensation control method is presented for addressing the issues in dynamically accurate positioning of a diamond cutting tool via the fast tool se…

Surface topography plays a critical role in the functional performance of machined freeform components, yet its assessment traditionally takes place only after manufacturing. This work presents a simulation-assisted framework for predicting the surface topography generated during freeform ball-end milling and using these predictions to support machining-strategy selection. Three finishing strateg…

The continuing evolution of transportation, aerospace, energy, electronics, and other high-performance engineering sectors is placing increasingly demanding requirements on manufacturing technologies [...]

Wafer-edge uniformity in semiconductor etching is a key quality metric directly linked to device yield and is strongly governed by the local sheath structure near the wafer edge-focus ring boundary. However, the relative effects of focus ring geometry, dielectric material, and applied voltage waveform on edge ion transport have not been systematically compared. In this study, a two-dimensional pa…

This study presents a parametric optimization model for the friction disc of a combined friction face milling cutter operating under intensive contact friction, high clamping forces, and cyclic thermomechanical loading. The computational framework integrates ANSYS Workbench, the Static Structural module, Design of Experiments (DOE), Kriging surrogate modeling, and Multi-Objective Genetic Algorith…

Electrical discharge machining (EDM) demonstrates significant advantages in machining difficult-to-cut materials, particularly those with high hardness and brittleness, owing to its thermally driven material removal mechanism in which the arc plasma serves as the heat source. However, machining performance varies markedly across different workpiece materials. Such differences are likely attributa…

Contact-rich manufacturing processes such as surface cleaning, deburring, and polishing require precise force regulation and complex trajectory tracking that are challenging to automate using conventional robot programming methods. Learning from Demonstration (LfD) offers a powerful alternative to transfer these expert skills from human operators to robotic systems. The objective of this study is…

This study investigates the effects of the rake angle and clearance angle of custom-manufactured HSS-E Co5 high-speed steel cutting tools on the Fc main cutting force, the Fp passive force component, the Ra and Rz surface roughness parameters, and chip morphology during orthogonal free cutting of EN AW-7075-T6 aluminum alloy. A dedicated experimental fixture was designed and manufactured for the …

The increasing demand for lightweight and corrosion-resistant structures has accelerated the use of AA5083 aluminium alloy in automotive, aerospace, marine and transportation industries owing to its excellent corrosion resistance, weldability and favourable strength-to-weight ratio. However, the fabrication of complex AA5083 components remains challenging because of limited formability, localised…

Precision glass molding is a promising yet challenging approach for fabricating Fresnel glass lenses, as their complex multi-ring microstructures tend to induce nonuniform glass flow and incomplete filling. To elucidate the filling behaviors under compression, a thermo-mechanically coupled finite element model was developed to simulate the molding process. The ring filling ratios of each ring and…

Glass additive manufacturing (AM) is a developing technology, particularly in comparison to metals and polymers, both of which have had their processes and applications extensively studied. Its potential lies in fabricating complex, even micrometric, geometries that are difficult or impossible to achieve via traditional molding, as well as in producing components with unique optical properties. T…

This paper presents a critical review of surface protection strategies for refurbished hydropower components, with emphasis on the manufacturing and materials-processing logic that links damage mechanisms, substrate condition, deposition route, microstructure, and service performance. The literature indicates that cavitation erosion, sediment abrasion, corrosion, and their synergistic interaction…

Hydrodynamic cavitation is increasingly investigated as a process-intensification technology for liquid processing and complex or waste-derived streams. Conventional Venturi cavitators rely on fixed geometries selected for nominal operating conditions, whereas practical processes may involve variable fluid properties, flow rates, pressure conditions, and treatment objectives. This mismatch can pr…

316L stainless-steel capillary tubes are important in medical devices, precision fluid transport and micro heat exchangers, but their slender geometry and dense passivation film make inner-surface finishing inefficient. This study proposes a stepwise chemical-assisted magnetorheological finishing (CMRF) process for 316L capillaries. The inner surface was first pretreated with hydrogen peroxide/ox…

Tool wear detection is essential for machining quality control and predictive maintenance, but conventional inspection is often manual, time-consuming, and operator-dependent. Existing learning-based visual methods still face challenges in jointly achieving reliable wear-type recognition, accurate wear-region localization, and quantitative wear-width measurement under shop-floor imaging condition…

This study investigates the influence of laser spot size (Ø100 µm vs. Ø50 µm) on the microstructure, transformation behavior, and hardness of Ti-51.17 at.%Ni shape memory alloy samples fabricated by laser powder bed fusion. Samples were produced using identical processing parameters covering laser powers of 50–150 W, scanning speeds of 500–750 mm/s, and matched volumetric energy densities (28–83 …

The dual reliance on surface-mount technology (SMT) and pin-through-hole (PTH) assembly lines in high-volume printed circuit board (PCB) manufacturing induces logistical bottlenecks, excessive operational costs, and elevated thermal stress on components. This study presents the optimization of a wireless detector terminal production line by integrating Pin-in-Paste (PiP) technology within a Six S…