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Metals
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Machining of Advanced Cutting Materials: Fundamentals, Modeling and Applications (Volume...
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Machining of Advanced Cutting Materials: Fundamentals, Modeling and Applications (Volume II)

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Computation and Simulation on Metals".

Deadline for manuscript submissions: closed (31 December 2023) | Viewed by 2361

Special Issue Editor

Prof. Dr. Sergey N. Grigoriev

E-Mail Website
Guest Editor
Department of High-Efficiency Processing Technology, Moscow State University of Technology, 127055 Moscow, Russia
Interests: processing by concentrated energy flows; laser processing; electrophysical machining; heat and hardening treatment; surface finishing and coating; powder metallurgy; nanomaterials; nanocoatings and thin films; thermal spray technologies; process diagnostics and monitoring
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Although advanced tool materials possess unique physical and mechanical properties such as high hardness, wear resistance, and heat resistance, their machinability is so low that it complicates manufacturing cutting tools and cutting inserts. At the same time, the development of new efficient technologies for machining cutting tools made of advanced materials is critically important due to the requirements around the accuracy and roughness of the tool surface being machined.

Today, multifactor mathematical modeling is the key theoretical instrument that facilitates, alongside laboratory experiments, resolving the aforementioned fundamental problems. Rational shaping of a tool of a given shape based on its geometry and tool material properties is a fast and cost-efficient way of increasing the tool operational properties and extending the tool life that in addition allows reducing the time needed to develop a prototype due to the reduction in the number and the complexity of laboratory experiments. One of the most important issues in manufacturing cutting tools from advanced tool materials is an analytical description of surfaces being machined needed for the assignment of rational tool trajectories. The most complex objects to be simulated and machined are double curvature surfaces such as helical surfaces and cutting edges designed based on them on shaped production cutting surfaces. Machining products with a curved directrix and generatrix is a complex dynamic process, which depends on the tool geometry and technological parameters of the machine, which in turn strongly depend on the properties of the tool material. Advancing the tool design by accounting for physical and mechanical properties of the tool material requires the application of contemporary mathematical methods, including the widely used finite element method (FEM).

The most common tools are cutters and drills with the cutting edge of a complex shape. Typically, such tools are endowed with a helical groove, whose shape and machining technology are largely controlled by the hardness and strength of the tool material, which in turn strongly depends on its chemical composition, structure, and grain size, with the latter being a critically important parameter controlling the tool curvature radius. Another important class of tools is assembly tools equipped with replaceable cutting inserts upon which wear-resistant coating is applied.  

We invite contributions from experimentalists, theorists, and modelers performing research on the machining of complex surfaces, including visualization of the contact between the workpiece and the cutting edges, grinding, electroerosion, milling, and other processes involved in shaping and application of advanced cutting materials.

Prof. Dr. Sergey N. Grigoriev
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • cutting tools
  • shaping of advanced cutting materials
  • grinding
  • electroerosion
  • milling
  • mathematical modeling
  • FEM in tool design and machining

Published Papers (2 papers)

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18 pages, 18944 KiB  
Article
Effect of Milling Strategy on the Surface Quality of AISI P20 Mold Steel
by Adel T. Abbas, Elshaimaa Abdelnasser, Noha Naeim, Khalid F. Alqosaibi, Essam A. Al-Bahkali and Ahmed Elkaseer
Metals 2024, 14(1), 48; https://doi.org/10.3390/met14010048 - 29 Dec 2023
Cited by 1 | Viewed by 944
Abstract
This paper explores the impact of various milling strategies, including up-milling, down-milling, and hybrid approaches, on the surface roughness of AISI P20 mold steel. The study is methodically divided into three stages to comprehensively understand the effects of these strategies. The first stage [...] Read more.
This paper explores the impact of various milling strategies, including up-milling, down-milling, and hybrid approaches, on the surface roughness of AISI P20 mold steel. The study is methodically divided into three stages to comprehensively understand the effects of these strategies. The first stage involves milling single slots with varying cutting parameters to establish baseline effects. The second stage examines the effects of consistent milling strategies (up-up and down-down) on surface quality. The third stage probes into hybrid strategies (up-down and down-up) to assess their effectiveness. Central to this investigation is not only the type of milling strategy but also how cutting speed and feed rate influence the resultant surface roughness. Our findings indicate that up-milling generally leads to a 22% increase in surface roughness compared to down-milling. This trend is visually verified by surface texture analyses. When comparing consistent strategies, up-up milling tends to produce rougher surfaces than down-down milling by approximately 25%, characterized by distinctive scratches and feed mark overlays. Remarkably, while the hybrid milling strategies do not exhibit significant differences in surface roughness, variations in cutting speed and feed rate play a crucial role. Specifically, at lower speeds, hybrid milling achieves smoother surfaces than the identical double milling mode, while at a cutting speed of 100 m/min, the double mode demonstrates a notable decrease in roughness. Additionally, this study introduces a color mapping simulation for machined pockets, validated by experimental results, to predict surface roughness based on the strategic history of milling, thereby offering valuable insights for optimizing milling processes. Full article
(This article belongs to the Special Issue Machining of Advanced Cutting Materials: Fundamentals, Modeling and Applications (Volume II))
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20 pages, 7107 KiB  
Article
Investigation of Situational Correlations of Wire Electrical Discharge Machining of Superhard Materials with Acoustic Emission Characteristics
by Sergey N. Grigoriev, Mikhail P. Kozochkin, Artur N. Porvatov, Alexander P. Malakhinsky and Yury A. Melnik
Metals 2023, 13(4), 775; https://doi.org/10.3390/met13040775 - 15 Apr 2023
Cited by 1 | Viewed by 1000
Abstract
The purpose of this research is to find relationships between the parameters of the acoustic emission signals accompanying the electroerosive processing with a wire electrode of metals and hard alloys and the most important process indicators. These indicators include an increase in the [...] Read more.
The purpose of this research is to find relationships between the parameters of the acoustic emission signals accompanying the electroerosive processing with a wire electrode of metals and hard alloys and the most important process indicators. These indicators include an increase in the concentration of erosion products in the interelectrode gap, an increase in the probability of wire electrode breakage, the efficiency of the supplied energy, the current productivity. This article presents the results of the study of acoustic emission signals during the processing of hard alloys with a cutting machine. The main focus is on the period preceding the breakage of the wire electrode. Changes in the parameters of acoustic emission a few seconds before failure are shown, and the possibility of preventing wire breakage by monitoring the parameters of acoustic emission signals is established. To evaluate the efficiency of the energy supplied to the processing zone, a dynamic model is proposed, with the help of which the processing efficiency is estimated by changing the transmission coefficients in one or several frequency ranges. To explain the situation that occurs in the processing zone with an increase in the concentration of erosion products, the article draws a parallel between electroerosive and laser processing, related to technologies of processing with concentrated flows of energy. Studies have shown that acoustic emission signals can be used to search for rational processing modes and improve automatic control systems for electroerosive equipment. Full article
(This article belongs to the Special Issue Machining of Advanced Cutting Materials: Fundamentals, Modeling and Applications (Volume II))
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