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Metals
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Advances in Machining Processes of Metallic Materials
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Advances in Machining Processes of Metallic Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (30 June 2023) | Viewed by 6915

Special Issue Editors

Dr. Kejia Zhuang

E-Mail Website
Guest Editor
School of Mechanical and Electronic Engineering, Wuhan University of Technology, Wuhan 430070, China
Interests: superalloy; metal cutting; surface integrity; cutting edge geometry
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Dahu Zhu

E-Mail Website
Guest Editor
School of Automotive Engineering, Wuhan University of Technology, Wuhan 430070, China
Interests: tool wear; cutting mechanism; robotic belt griding; surface roughness

Special Issue Information

Dear Colleagues,

It is a great honor and privilege to be involved as Guest Editors of a Special Issue of Metals focusing on “Advances in Machining Processes of Metallic Materials”. We are pleased to invite you to contribute a research paper or review to this Special Issue. We believe it will become a very important Special Issue with your support.

Metallic materials play a significant role in the development of modern science, industry, and technology. They have a broad range of applications in various engineering fields. Proper machining processes can lead to obtaining proper surface integrity and enhancing service performance. The scope of the Special Issue is to publish outstanding papers presenting advances in the field of machining processes of metallic materials. In this Special Issue, we aim to collect a set of contributions in, but not limited to, the following topics:

  • Conventional and non-conventional machining processes;
  • High-efficiency machining process materials;
  • Innovations in machining methods (tools, characterization, etc.);
  • Optimization of process parameters;
  • Surface integrity of machined components;
  • Improvement of the performance of the machining process;
  • Manufacturing of complex parts with metallic materials;
  • Cutting tool wear, tool life, and cutting tool design;
  • Modeling of processing signature.

Articles addressing all aspects of machining of metallic materials, including material processing, design and development of equipment and cutting tools, and the surface integrity of machining processes are welcome. Full papers, communications, and reviews are welcome for submission.

Dr. Kejia Zhuang
Prof. Dr. Dahu Zhu
Guest Editors

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

  • metallic materials
  • machining process
  • cutting mechanism
  • tool wear
  • surface integrity
  • tool monitoring

Published Papers (4 papers)

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Research

12 pages, 6062 KiB  
Article
Deformation and Fracture Characterization of an Mg-Sn-Ca Alloy Using 3D Processing Maps
by Chenchen Zhi, Zhenyu Wu, Junyi Lei, Zhiquan Huang, Haijie Xv, Yanchun Zhu, Weitao Jia, Pengtao Liu and Lifeng Ma
Metals 2023, 13(4), 645; https://doi.org/10.3390/met13040645 - 24 Mar 2023
Cited by 3 | Viewed by 1048
Abstract
The deformation and fracture characterization of an Mg−2Sn−1Ca alloy were studied through uniaxial isothermal compression tests. The flow stress curves, the efficiency of power dissipation, the instability parameter and the fracture behavior of an Mg−2Sn−1Ca alloy under the condition of various hot working [...] Read more.
The deformation and fracture characterization of an Mg−2Sn−1Ca alloy were studied through uniaxial isothermal compression tests. The flow stress curves, the efficiency of power dissipation, the instability parameter and the fracture behavior of an Mg−2Sn−1Ca alloy under the condition of various hot working parameters were investigated according to the experimental data. Processing maps were established by superimposing the instability map over the power dissipation map. It was found that flow stress reduces with increases in the deformation temperature and decreases in the strain rate. The processing of Mg−2Sn−1Ca alloys should avoid the instability region in which the conditions are high strain under high temperature and low strain under low temperature. At 473 K or a high strain rate, unidirectional cracks and fish scale cracks can be produced, and cracks can be avoided under the optimum processing area of 623–723 K/0.001–0.1 s−1. Full article
(This article belongs to the Special Issue Advances in Machining Processes of Metallic Materials)
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17 pages, 5181 KiB  
Article
Spatial Path Planning for Robotic Milling of Automotive Casting Components Based on Optimal Machining Posture
by Hao Wu, Yudi Wang, Xiaoxu Wei and Dahu Zhu
Metals 2022, 12(8), 1271; https://doi.org/10.3390/met12081271 - 28 Jul 2022
Cited by 6 | Viewed by 1509
Abstract
The robotic milling of automotive casting components can effectively reduce human participation in the production process and enhance production efficiency and quality, but the premise addresses the reasonable planning of machining paths. To address major challenges, this paper proposes a spatial path planning [...] Read more.
The robotic milling of automotive casting components can effectively reduce human participation in the production process and enhance production efficiency and quality, but the premise addresses the reasonable planning of machining paths. To address major challenges, this paper proposes a spatial path planning method for the robotic milling of casting flash and burrs on an automotive engine flywheel shell based on the optimal machining posture. Firstly, an improved stereolithography slicing algorithm in arbitrary tangent plane direction is put forward, which solves the problem that the existing stereolithography slicing algorithm cannot accurately extract the contour of complex components. Secondly, the contour path curve fitting of the slicing points of the flywheel shell is realized based on the B-spline curve. Next, a machining posture evaluation function is established based on the robot’s stiffness performance, and the optimal machining posture is solved and verified with simulation according to the machining posture evaluation function and posture interpolation. Finally, the experiments indicate that the proposed method can significantly enhance the machining quality, with an average allowance height of 0.33 mm, and reduce the machining time to 9 min, compared with the conventional manual operation, both of which satisfy the machining requirements. Full article
(This article belongs to the Special Issue Advances in Machining Processes of Metallic Materials)
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17 pages, 3578 KiB  
Article
Theoretical Analysis of Grinding Wheel Deflection Angle on Peripheral Grinding Parameters and Grinding Force
by Changhao Chen, Bin Chen, Chaoqun Wu, Xinghua Gu, Xuehai Liu and Feng Guo
Metals 2022, 12(7), 1209; https://doi.org/10.3390/met12071209 - 17 Jul 2022
Viewed by 1558
Abstract
The peripheral surface of the grinding wheel can grind the rail according to the envelope of the contour of the rail surface, thus a fuller and smoother rail surface can be obtained. Specifically, a better grinding effect can be obtained in that the [...] Read more.
The peripheral surface of the grinding wheel can grind the rail according to the envelope of the contour of the rail surface, thus a fuller and smoother rail surface can be obtained. Specifically, a better grinding effect can be obtained in that the end face of the grinding wheel deviates from the longitudinal section of the rail at a certain angle. Based on the traditional grinding technology theory, the mathematical models of the peripheral grinding parameters (kinematic contact arc length, wheel-rail grinding contact area, and maximum undeformed chip thickness) and the grinding force are established, in which the angle exists between the grinding wheel end face and the rail longitudinal section. The main influence of grinding wheel circumferential speed, grinding wheel kinematic speed, and the deflection angle of the grinding wheel end face on the grinding parameters and the force are analyzed. The result shows that: when there is angle θ in the models, the ratios of peripheral grinding parameters between up-grinding and down-grinding varies monotonically with the increase in vm, and their maximum variation range is about 12%, vs has the greatest influence on the peripheral grinding parameters, and the maximum variation range of the ratios is about 20% when the vs is 10 m/s. With the increase in the grinding width, Fa’ cannot be ignored and will increase gradually with the increase in angle θ. The analysis and conclusion have guiding significance for the structural design, grinding control strategy, and experimental research regarding rail curved surface grinding equipment. Full article
(This article belongs to the Special Issue Advances in Machining Processes of Metallic Materials)
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11 pages, 4226 KiB  
Article
Formation Mechanism and Control of Solidification Cracking in Laser-Welded Joints of Steel/Copper Dissimilar Metals
by Zhongmei Gao, Yuye Yang, Lei Wang, Bin Zhou and Fei Yan
Metals 2022, 12(7), 1147; https://doi.org/10.3390/met12071147 - 5 Jul 2022
Cited by 8 | Viewed by 2122
Abstract
The solidification cracking behavior in laser welds of steel/copper dissimilar metals was systematically investigated. T2 copper and SUS304 stainless steel were used in the study. The results showed that the occurrence of solidification cracking in welds was the synergistic effect of ε phase [...] Read more.
The solidification cracking behavior in laser welds of steel/copper dissimilar metals was systematically investigated. T2 copper and SUS304 stainless steel were used in the study. The results showed that the occurrence of solidification cracking in welds was the synergistic effect of ε phase liquation, inclusions and composition segregation. During the welding process, the liquation of grain boundaries substantially reduced the cohesion between adjacent grains, as well as the resistance for intergranular crack propagation. The composition segregation inside the grains could induce lattice distortion, thus reducing the plastic deformation capacity of the material itself and concurrently increasing the susceptibility to cracks. In addition, an effective solution for inhibiting solidification cracking was proposed by using an oscillating laser, and the inhibition mechanism was further discussed. Laser oscillating welding significantly promoted grain refinement, solute diffusion and the formation of uniformly distributed ε-Cu precipitated phases in welds. It can improve the intergranular bonding, reduce the susceptibility to solidification cracking and increase the resistance to plastic deformation. The tensile strength of joints using laser oscillating welding is 251 MPa, 35.7% more than 185 MPa using laser welding. Meanwhile, the strain of joints using laser oscillating welding is 3.69, a 96% increase compared to 1.88 using laser welding. Full article
(This article belongs to the Special Issue Advances in Machining Processes of Metallic Materials)
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