International Journal of Mechatronics and Manufacturing Systems (6 papers in press)

Regular Issues

• Tool wear and surface integrity in the cryogenic cutting of high entropy alloy Ni40Fe30Co20Al10  
  by Xiaoxia Zhang, Lihu Wang, Yang Qiao, Xiuli Fu, Guoliang Liu, Xiangyu Wang 
  Abstract: High entropy alloys exhibit exceptional mechanical properties but present machinability constrains. This study investigates the effect of cutting speeds (100/200/300 m/min) and cooling conditions on tool wear mechanisms and surface integrity during the cutting of Ni40Fe30Co20Al10 HEA. Experimental results demonstrate that cryogenic cooling generates higher cutting forces than dry and emulsion cooling. Under different cutting parameters, the rake face of the tool was mainly cratering wear and the flank wear was mainly adhesive. Compared with dry cutting and emulsion cooling cutting, cryogenic cutting inhibited tool wear. After cutting, the workpiece surface retains a face-centred cubic (FCC) structure, with cryogenic cooling promoting grain refinement and reducing surface roughness. Observed surface defects include material adhesion, feed marks, and micro-pits. Overall, Cryogenic cutting significantly mitigated cutting heat, resulting in reduced temperatures during the machining process. This method promoted uniform material deformation, minimised tool wear, and enhanced the overall quality of the machined surface.
  Keywords: cryogenic cutting; high entropy alloys; tool wear; grain refinement; surface integrity.
  DOI: 10.1504/IJMMS.2025.10072806
   
  
• Fractional-order PID Control of Valve Opening in a Centrifugal Pump System Using Simulation  
  by Yucheng Pan, Wang YanWei 
  Abstract: In response to the control challenges commonly observed in centrifugal pump systems particularly the insufficient accuracy and low stability associated with conventional proportional-integral (PI) and proportional-integral-derivative (PID) controllers this paper presents a mathematical model of the valve opening control system using MATLAB Simulink. The study determines the optimal control range for valve opening within the pump, pipeline, and valve subsystems. A novel control scheme is then developed based on a fractional-order PID (FOPID) algorithm in combination with the Oustaloup filter for approximating non-integer order dynamics. Simulation results demonstrate that, under identical proportional, integral, and derivative gains and a target valve opening of 75%, the proposed FOPID controller achieves an 8.7% reduction in overshoot and a 5.6 s decrease in settling time compared to the traditional PID controller. These improvements indicate significantly enhanced dynamic performance and system stability. The results provide a valuable foundation for future research and development of advanced valve control strategies in centrifugal pump systems.
  Keywords: Centrifugal pump system; Valve opening; Optimal valve opening range; Fractional-order PID; Simulation.
  DOI: 10.1504/IJMMS.2025.10073189
   
  
• Adaptive Obstacle Avoidance Technology for Mobile Robots in Indoor Environments  
  by Xin Zhang, Wei Li, JinBao Sun, KunJian Liu, Zhe Zhang 
  Abstract: Path obstacle avoidance technology is essential for intelligent robots to navigate complex environments effectively. Current methods are costly and struggle with the challenges posed by static and dynamic obstacles indoors. This study addresses these issues by optimizing monocular image processing through Mobile Net v4 and enhancing deep Q-networks with velocity constraints and improved reward selection. A new model was developed, achieving optimal performance at a linear velocity of 0.75 m/s and an angular velocity of ?/5 rad/s. Key results include a Q-value of 4.6, an average reward of 94, a 98.3% success rate in obstacle avoidance, and an average running time of 3.1 seconds. This research significantly enhances the accuracy and efficiency of indoor robot navigation.
  Keywords: Indoor; Path; Obstacle avoidance; Deep reinforcement learning; Image.
  DOI: 10.1504/IJMMS.2025.10073258
   
  
• Intelligent Condition Monitoring of PMSM-Based Drive Systems using a Swin-CNN Fusion Network for Manufacturing Applications  
  by Hao Yu, Hao Zhang, Xiaojing Liu 
  Abstract: Permanent Magnet Synchronous Motors (PMSMs) are widely employed in advanced manufacturing and mechatronic systems, where early detection of mechanical faults is vital for system reliability and productivity. This paper presents a novel current-based radial misalignment diagnosis framework for PMSM-driven systems using a dual-branch Swin-CNN fusion network. The proposed method integrates time-frequency and spectral domain analysis through Continuous Wavelet Transform (CWT) and Fast Fourier Transform (FFT), respectively. A two-stream deep learning architecture is introduced, combining a 2D Swin Transformer for global time-frequency feature modeling and a 1D CNN enhanced with Convolutional Block Attention Module (CBAM) for frequency-domain emphasis. Experimental results on a lab-scale PMSM setup demonstrate an average classification accuracy of 98.125% under varying fault levels. The proposed approach offers a cost-efficient, non-invasive solution for condition monitoring in intelligent manufacturing systems, supporting predictive maintenance and enhanced equipment availability in Industry 4.0 environments.
  Keywords: Permanent Magnet Synchronous Motor (PMSM); Sliding Window Attention Network; Convolutional Neural Network (CNN); Attention Mechanism; Fault Diagnosis.
  DOI: 10.1504/IJMMS.2025.10073259
   
  
• Development of a unified thermal model for Wire Electrical Discharge Machining: integration of multi-discharge dynamics and plasma flush efficiency  
  by Mariangela Quarto, Gianluca D'Urso 
  Abstract: The wire electrical discharge machining (WEDM) process is characterized by a complex material removal method based on the generation of electrical discharges in the gap between the tool (wire) and the workpiece. Research efforts have been focused on optimizing the process parameters so as for the productivity of the process to be increased. Although extensive research exists on various aspects of WEDM, comprehensive thermal modelling remains underdeveloped. This study addresses the gaps by integrating multiple existing thermal models to define a unified, multi-discharge model that accurately represents continuous and repetitive discharges. The new model incorporates critical factors such as Plasma Flush Efficiency (PFE) and the elliptical shape of craters, offering a more precise depiction of thermal phenomena and their correlation with process parameters. Implemented within a Finite Element Method (FEM) environment, the model was validated against experimental data from cutting tests on 316L stainless steel. The results demonstrated the model's capability to predict cutting geometry and process time with high accuracy, achieving a prediction error of 0.38% for cutting width and 12.20% for cutting time.
  Keywords: wire-EDM; thermal model; simulation.
  DOI: 10.1504/IJMMS.2025.10073292
   
  
• UIO-Based Innovative Resilience Strategies for False Data Injection Attacks in Multi-Area Power Systems  
  by Zhou Zheng 
  Abstract: False data injection (FDI) attacks threaten the security and stability of multi-area interconnected power systems by compromising control accuracy and state estimation. This paper proposes a defense framework integrating event-triggered control and the Unknown Input Observer (UIO) technique to mitigate these attacks. Event-triggered control reduces unnecessary data transmission while ensuring real-time monitoring of critical system states, and UIO enhances detection by estimating unknown inputs. A comprehensive model of multi-area interconnected power systems is developed to evaluate the impact of FDI attacks and the proposed defense strategy. Simulation results demonstrate that the proposed method significantly outperforms traditional data integrity verification approaches in terms of detection accuracy and system resilience, highlighting its potential for practical application in securing critical power infrastructures.
  Keywords: System Dynamics; Power System Modeling; Adaptive Control; Unknown Input Observer; False Data Injection.
  DOI: 10.1504/IJMMS.2025.10073424