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Applied Sciences
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Advances in Machining Process for Hard and Brittle Materials
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Advances in Machining Process for Hard and Brittle Materials

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: 20 December 2024 | Viewed by 4813

Special Issue Editor

Dr. Shang Gao

E-Mail Website
Guest Editor
School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, China
Interests: ultra-precision machining; nanomechanics; surface science; mechanical characterization

Special Issue Information

Dear Colleagues,

Hard and brittle materials, such as semiconductors, advanced ceramics, and optical glass, are widely applied in aerospace, electronic devices, and biomedicine. Hard and brittle material machining technology is an indispensable aspect in modern manufacturing, playing a crucial role in enhancing product performance and quality. This Special Issue aims to gather the latest research on the hard and brittle material machining processes, providing new insights and prospects for academia and industry. Importantly, the novel abrasive tool and ultrasonic technology have brought great progress in the processing efficiency and quality for hard and brittle materials. Moreover, the emergence of multi-field composite techniques provides new possibilities for achieving a high-precision surface on hard and brittle materials. Despite challenges encompassing material fracture, residual stresses, and subsurface damage, we possess the confidence to propel hard and brittle material machining toward a more promising future. We sincerely welcome researchers to submit innovative works related to hard and brittle material machining processes, and jointly promote the advancement and application of this field.

Dr. Shang Gao
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. Applied Sciences is an international peer-reviewed open access semimonthly 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 2400 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

  • hard and brittle materials
  • abrasive machining
  • laser-assisted machining
  • ultrasonic machining
  • multi-field
  • removal mechanism
  • brittle–ductile transitions
  • molecular dynamics
  • multiscale model
  • surface damage

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Published Papers (3 papers)

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Research

18 pages, 18015 KiB  
Article
Sustainable Diamond Burnishing of Chromium–Nickel Austenitic Stainless Steels: Effects on Surface Integrity and Fatigue Limit
by Jordan Maximov, Galya Duncheva, Angel Anchev, Vladimir Dunchev, Kalin Anastasov and Yaroslav Argirov
Appl. Sci. 2024, 14(19), 9031; https://doi.org/10.3390/app14199031 - 6 Oct 2024
Viewed by 728
Abstract
This study aims to evaluate the influence of lubrication and cooling conditions in the diamond burnishing (DB) process on the surface integrity and fatigue limit of chromium–nickel austenitic stainless steels (CNASSs) and, on this basis, identify a cost-effective and sustainable DB process. Evidence [...] Read more.
This study aims to evaluate the influence of lubrication and cooling conditions in the diamond burnishing (DB) process on the surface integrity and fatigue limit of chromium–nickel austenitic stainless steels (CNASSs) and, on this basis, identify a cost-effective and sustainable DB process. Evidence was presented that DB of CNASS performed without lubricating cooling liquid satisfies the requirements for a sustainable process: the three key sustainability dimensions (environmental, economic, and social) are satisfied, and the cost/quality ratio is favorable. DB was implemented with the same values of the main governing factors; however, four different lubrication and cooling conditions were applied: (1) flood lubrication (process F); (2) dry without cooling (process D); (3) dry with air cooling at a temperature of −19 °C (process A); and (4) dry with nitrogen cooling at a temperature of −31 °C (process N). Conditions A and N were realized via a device based on the principle of vortex tubes. All four DB processes provide mirror-finished surfaces with Ra roughness parameter values from 0.041 to 0.049 μm, zones with residual compressive stresses deeper than 0.5 mm, and increases in the specimens’ fatigue limit (as determined by the accelerated Locati’s method) compared to turning and polishing. Processes F and D produce the highest microhardness on the surface and at depth. The process D introduces maximum compressive residual axial and hoop stresses in the surface layer. The dry DB processes (D, A, and N) form a submicrocrystalline structure with high atomic density, which is most strongly developed under process D. When high fatigue strength is required, DB with air cooling should be chosen, as it provides a more favorable cost/quality ratio, whereas dry DB without cooling is the most suitable choice for applications that require increased wear resistance. Full article
(This article belongs to the Special Issue Advances in Machining Process for Hard and Brittle Materials)
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18 pages, 11113 KiB  
Article
Effect of Wheel Path in Raster Grinding on Surface Accuracy of an Off-Axis Parabolic Mirror
by Jianhe Li, Honggang Li, Xiaoguang Guo, Renke Kang and Shang Gao
Appl. Sci. 2023, 13(19), 11096; https://doi.org/10.3390/app131911096 - 9 Oct 2023
Viewed by 1056
Abstract
Off-axis parabolic mirrors have extensive applications in X-ray optics, with the precision of their curvature directly impacting grazing-incidence focusing performance. Notably, the off-axis parabolic surface has non-rotating and non-symmetrical characteristics. Ultra-precision raster grinding utilizing a diamond wheel is a common method. Crucially, establishing [...] Read more.
Off-axis parabolic mirrors have extensive applications in X-ray optics, with the precision of their curvature directly impacting grazing-incidence focusing performance. Notably, the off-axis parabolic surface has non-rotating and non-symmetrical characteristics. Ultra-precision raster grinding utilizing a diamond wheel is a common method. Crucially, establishing an optimal wheel path stands as the key to ensuring surface accuracy during off-axis paraboloid grinding. In this study, according to the double curvature property of an off-axis parabolic surface, two different wheel paths were compared: one tracing the meridian direction (parabolic generatrix) and the other following the arc vector direction (arc). The results showed that the wheel path in raster grinding stepping along the arc vector direction can obtain a smaller scallop height and higher surface accuracy. The surface accuracy of one step along the arc vector direction is 9.6 μm, and that of the other step along the meridian direction is 32.6 μm. A model of the scallop height was established based on the relative relationship between adjacent wheel paths, and the error is within 5%. According to the correlation between scallop height and shape error, we conducted an analysis of the spatial distribution of shape errors under varying wheel paths. The wheel path that steps along the arc vector is more suitable for raster grinding of the off-axis paraboloid. The above study can provide theoretical guidance for the wheel path planning of off-axis parabolic mirrors with high surface accuracy. Full article
(This article belongs to the Special Issue Advances in Machining Process for Hard and Brittle Materials)
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25 pages, 9121 KiB  
Article
WASPAS Based Multi Response Optimization in Hard Turning of AISI 52100 Steel under ZnO Nanofluid Assisted Dual Nozzle Pulse-MQL Environment
by Saswat Khatai, Ramanuj Kumar, Amlana Panda and Ashok Kumar Sahoo
Appl. Sci. 2023, 13(18), 10062; https://doi.org/10.3390/app131810062 - 6 Sep 2023
Cited by 3 | Viewed by 2537
Abstract
Hard turning is an emerging machining technology that evolved as a substitute for grinding in the production of precision parts from hardened steel. It offers advantages such as reduced cycle times, lower costs, and environmental benefits over grinding. Hard turning is stated to [...] Read more.
Hard turning is an emerging machining technology that evolved as a substitute for grinding in the production of precision parts from hardened steel. It offers advantages such as reduced cycle times, lower costs, and environmental benefits over grinding. Hard turning is stated to be difficult because of the high hardness of the workpiece material, which causes higher tool wear, cutting temperature, surface roughness, and cutting force. In this work, a dual-nozzle minimum quantity lubrication (MQL) system’s performance assessment of ZnO nano-cutting fluid in the hard turning of AISI 52100 bearing steel is examined. The objective is to evaluate the ZnO nano-cutting fluid’s impacts on flank wear, surface roughness, cutting temperature, cutting power consumption, and cutting noise. The tool flank wear was traced to be very low (0.027 mm to 0.095 mm) as per the hard turning concern. Additionally, the data acquired are statistically analyzed using main effects plots, interaction plots, and analysis of variance (ANOVA). Moreover, a novel Weighted Aggregated Sum Product Assessment (WASPAS) optimization tool was implemented to select the optimal combination of input parameters. The following optimal input variables were found: depth of cut = 0.3 mm, feed = 0.05 mm/rev, cutting speed = 210 m/min, and flow rate = 50 mL/hr. Full article
(This article belongs to the Special Issue Advances in Machining Process for Hard and Brittle Materials)
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