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Machines
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Machine Tools, Advanced Machining and Ultraprecision Machining
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Machine Tools, Advanced Machining and Ultraprecision Machining

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Advanced Manufacturing".

Deadline for manuscript submissions: closed (30 April 2023) | Viewed by 7715

Special Issue Editors

Prof. Dr. Adriano Fagali de Souza

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Guest Editor
Research group on Computer Aided Manufacturing (GPCAM), Federal University of Santa Catarina (UFSC), Dona Francisca, 8300, Joinville 89219-600, SC, Brazil
Interests: machining; CAD/CAM; Industry 4.0
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Luis Norberto López De Lacalle

E-Mail Website
Guest Editor
The Aeronautics Advanced Manufacturing Center-CFAA, 48170 Zamudio, Biscay, Spain
Interests: manufacturing process
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Álisson Rocha Machado

E-Mail Website
Guest Editor
Graduate Program in Mechanical Engineering, Pontifícia Universidade Católica do Paraná—PUCPR, Curitiba 80215-901, PR, Brazil
Interests: machining processes
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Alessandro Roger Rodrigues

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Universidade de São Paulo, Av. Trabalhador São-Carlense, 400, Centro, São Carlos CEP 13566-590, SP, Brazil
Interests: machining processes

Special Issue Information

Dear Colleagues,

Machine tools and machining processes form the basis of any developed economy, resulting in the increasing demand for micro- and ultraprecision products and components in recent decades. The novel era of machine tool designs and CNC controllers associated with Industry 4.0 technologies represents a driving force for future industries.

For the manufacture of small and ultraprecision parts, two scopes of this manufacturing chain must be considered: first, from the machines point of view, including advanced machine designs, kinematics, structural materials, CNC controllers as well as the CNC codes generated by CAD/CAM systems, all being relevant sources to guaranty the precision of the manufactured parts and the reduction in machining time. Moreover, Industry 4.0 brought the possibility of communicating between CNC and data clouds, today having become a necessity, for monitoring the production, process and machine itself, as well as bringing the possibility for controlling the machine with a remote app.

On the order hand, from the process point of view, novel cutting tool technologies, such as for geometry, materials and coatings, advances in machining strategies and the materials to be machined have presented challenges in high-performance and ultraprecision machining.

Together, both scopes are considered contemporary industry challenges. Taking this scenario into account, this Special Issue aims to provide a forum for researchers and practitioners to exchange their latest theoretical and engineering achievements, as well as to identify critical issues and challenges for future studies concerning machine tools and ultraprecision machining. Experimental research field condition results are especially encouraged for submission; theoretical papers accepted into this Special Issue are expected to contain original ideas and potential solutions to real problems.

Topics include, but are not limited to, the following domains:

  • Case studies of ultraprecision machining and micromachining.
  • Cutting tools: materials, geometry and coatings.
  • Cutting fluids.
  • Inspection of ultraprecision parts.
  • Machine design: structural and kinematic.
  • Machining process modelling and simulation.
  • Industry 4.0: monitoring and controlling the machine, process and the manufactured parts.
  • Controller: CNC interpolation, control loop, precision and high-speed processing.
  • Modal analysis, stiffness of the tool holder/cutting tool and part fixture.
  • Machine modelling and simulation.
  • CAD/CAM: ultraprecision tool path generation.
  • Machine sensing.
  • Interface communication: HMI, CNC and data cloud

Prof. Dr. Adriano Fagali de Souza
Prof. Dr. Luis Norberto López De Lacalle
Prof. Dr. Álisson Rocha Machado
Prof. Dr. Alessandro Roger Rodrigues
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. Machines 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 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

  • ultraprecision machine tools
  • high-performance CNC
  • ultraprecision machining process
  • tool paths
  • machine simulation
  • machining process simulation
  • Industry 4.0

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (3 papers)

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Research

12 pages, 3629 KiB  
Article
An Upper Bound Energy Formulation of Free-Chip Machining with Flat Chips and an Alternative Method of Determination of Cutting Forces without Using the Merchant’s Circle Diagram
by Hillol Joardar, Nitai Sundar Das, Barun Haldar, Kalipada Maity, Naser Abdulrahman Alsaleh and Sabbah Ataya
Machines 2023, 11(9), 853; https://doi.org/10.3390/machines11090853 - 25 Aug 2023
Viewed by 2309
Abstract
An upper bound analysis of free-chip machining has been carried out, where the tool cutting and friction forces were determined from the deformation energy dissipated during the chip separation process. The method employed was based on the classical upper bound theorem, as formulated [...] Read more.
An upper bound analysis of free-chip machining has been carried out, where the tool cutting and friction forces were determined from the deformation energy dissipated during the chip separation process. The method employed was based on the classical upper bound theorem, as formulated by Prager and Hodge, and Drucker, Prager, and Greenberg, and its modification by Collins, to deal with the metal forming processes involving coulomb friction. A straight shear plane and coulomb friction at the chip/tool interface were assumed and the energy required for cutting was calculated from a strain rate/velocity field that was constructed using the method proposed by Collins. Cutting forces, thrust forces, tool/chip contact lengths, and chip thickness ratios were determined for different tool rake angles and friction conditions. The theoretical results were also compared with some experimental results that are available in the published literature. The comparison between the two was not found to be satisfactory. This may be due to the non-unique nature of the machining process, as stated by Hill and demonstrated by other authors. The results calculated from the present method of ”energy balance” were also found to be in agreement with those obtained by Merchant using the principle of ”force balance”. Full article
(This article belongs to the Special Issue Machine Tools, Advanced Machining and Ultraprecision Machining)
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13 pages, 8436 KiB  
Article
Performance and Wear of Diamond Honing Stones
by Georg Mahlfeld and Klaus Dröder
Machines 2023, 11(4), 502; https://doi.org/10.3390/machines11040502 - 21 Apr 2023
Viewed by 1981
Abstract
Honing is one of the most precise processes for the production of tribologically highly loaded cylindrical bores in different areas of technology. The honing stone specifications influence the process performance to a large extent. During machining, the honing stones are in permanent contact [...] Read more.
Honing is one of the most precise processes for the production of tribologically highly loaded cylindrical bores in different areas of technology. The honing stone specifications influence the process performance to a large extent. During machining, the honing stones are in permanent contact with the workpiece and subject to high mechanical loads. High strength steel and latest coating materials cause additional stress on the honing stones and induce increased wear. The objective is to determine process information for these material properties to support an effective process design. In experiments, the performance and the wear rates of several honing stone specifications were investigated. In this publication, the observed wear mechanisms are analysed and influencing factors for reduced wear are outlined. Full article
(This article belongs to the Special Issue Machine Tools, Advanced Machining and Ultraprecision Machining)
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23 pages, 6293 KiB  
Article
Kinematic Calibration Method for Large-Sized 7-DoF Hybrid Spray-Painting Robots
by Yutian Wang, Mengyu Li, Junjian Wang, Qinzhi Zhao, Jun Wu and Jinsong Wang
Machines 2023, 11(1), 20; https://doi.org/10.3390/machines11010020 - 24 Dec 2022
Cited by 17 | Viewed by 2249
Abstract
Large-sized seven-degrees-of-freedom (7-DoF) hybrid spray-painting robots combine ample working space and high flexibility, making them lucrative for the spray painting of aircraft and rocket surfaces. However, their kinematic calibration is hindered by gravitational deformation, which problem is addressed in this study by introducing [...] Read more.
Large-sized seven-degrees-of-freedom (7-DoF) hybrid spray-painting robots combine ample working space and high flexibility, making them lucrative for the spray painting of aircraft and rocket surfaces. However, their kinematic calibration is hindered by gravitational deformation, which problem is addressed in this study by introducing a rigid-flexible coupling error modeling method. The latter combines the finite element method (FEM) and stiffness matrix method to assess the spatial gravitational deformation of a hybrid robot, which is then introduced into a geometric error model to establish the rigid-flexible coupling error identification model. Given many redundant parameters in the identification model for 7-DoF robots, these parameters are classified and simplified using the nonlinear least-square regularization method for parameter identification. Combining the inverse solution of 7-DoF spray-painting robots with dynamic characteristics considered, an error compensation method for 7-DoF robots is proposed. The kinematic calibration test results strongly indicate that position errors are significantly reduced with gravity compensation taken into consideration, and error convergence speed increases, demonstrating that the kinematic calibration method is feasible and can effectively improve the accuracy of spray-painting robots. The mean errors in the X- and Y-directions are reduced by 20 and 17%, respectively, compared to the conventional method. The proposed method is instrumental in the accurate kinematic calibration of large-sized 7-DoF hybrid robots. Full article
(This article belongs to the Special Issue Machine Tools, Advanced Machining and Ultraprecision Machining)
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