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New Advances in Precision Machining
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New Advances in Precision Machining

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Material Processing Technology".

Deadline for manuscript submissions: closed (30 September 2024) | Viewed by 6942

Special Issue Editor

Dr. Mehmet Erdi Korkmaz

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Karabük University, Karabük, Turkey
Interests: machining; mechanics of material; finite element method

Special Issue Information

Dear Colleagues,

The manufacturing of high-precision parts is always an adventure in itself, and the complexity of the parts is determined not only by the manufacturing tolerances but also by the material and the geometric forms that it has. In the manufacturing industry, the term "precision machining" refers to single-digit tolerances at the micron level, while ultra-precision machining refers to submicron values. Precision machining emerges as a need for many industries: aerospace, fluids, medical, dental, sports, and high-tech fields. New technological areas, where smaller and more complex parts are being used intensively, are increasingly in need of precision machining processes.

This Special Issue addresses numerous research challenges in different fields, including precision machining technologies, novel machining processes, cutting mechanics, surface generation mechanisms, novel machine design, advanced sensing, machine metrology, accurate control of the machining process through the modeling and simulation of precision machining processes, materials sciences, measurement and on-machine metrology, as well as advanced applications for functional uses. This Special Issue aims to provide a good collection of the latest research results and findings in recent advances in precision machining technology and applications.

Dr. Mehmet Erdi Korkmaz
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. 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.

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

Published Papers (4 papers)

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Research

18 pages, 10072 KiB  
Article
Determination and Verification of the Johnson–Cook Constitutive Model Parameters in the Precision Machining of Ti6Al4V Alloy
by Piotr Löschner, Munish Kumar Gupta, Piotr Niesłony, Mehmet Erdi Korkmaz and Muhammad Jamil
Machines 2024, 12(10), 709; https://doi.org/10.3390/machines12100709 - 5 Oct 2024
Viewed by 856
Abstract
Numerical simulations of the cutting process play a key role in manufacturing and cost optimization. Inherent in finite element analysis (FEA) simulations is the correct description of material behavior during machining. For this purpose, various material models are used to describe the behavior [...] Read more.
Numerical simulations of the cutting process play a key role in manufacturing and cost optimization. Inherent in finite element analysis (FEA) simulations is the correct description of material behavior during machining. For this purpose, various material models are used to describe the behavior of the material in the range of high deformation, high temperature values, and high strain rates. Very often the Johnson–Cook (JC) material model is used for this purpose; however, the correct determination of the material constants of this model is a key aspect. Therefore, this paper presents a procedure for determining the material constants of the JC model using an analytical method based on normalized tensile and compression testing of the material for different strain rates over a wide temperature range. After determining the material constants, the authors conducted numerical simulations of the orthogonal turning of Ti6Al4V titanium alloy using the obtained constants. Validation of the obtained results with those obtained in experimental studies was also carried out. The outcomes demonstrated that the difference between FEM simulation and experimental tests did not exceed 0.02 mm (14%) in the case of chip thickness,. Much smaller differences were obtained for the temperature in the cutting zone, where the maximum difference was about 45 °C (4%). Comparing the components of the cutting force, we found that, in the case of the main cutting force, in most cases, the differences did not exceed 70 N (8%). After the verification of the obtained results, it was also found that the determined material constants of the Johnson–Cook model can be successfully used in FEM modeling of the cutting process of Ti6Al4V titanium alloy for the adopted range of values of technological parameters. Full article
(This article belongs to the Special Issue New Advances in Precision Machining)
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18 pages, 11929 KiB  
Article
Investigation of Single Grain Grinding of Titanium Alloy Using Diamond Abrasive Grain with Positive Rake Angle
by Jiu Yin, Rushui Sun, Chuanbo Ming, Chang Chen and Shuai Zeng
Machines 2024, 12(7), 451; https://doi.org/10.3390/machines12070451 - 2 Jul 2024
Viewed by 926
Abstract
Traditional grinding, which is predominantly performed with a negative rake angle (NRA), can be transformed into grinding with a positive rake angle (PRA) by employing femtosecond pulsed laser technology to modify the apex angle of the grains to be less than 90°. This [...] Read more.
Traditional grinding, which is predominantly performed with a negative rake angle (NRA), can be transformed into grinding with a positive rake angle (PRA) by employing femtosecond pulsed laser technology to modify the apex angle of the grains to be less than 90°. This innovative approach aims to reduce grinding forces and grinding temperatures while improving the surface quality of typical hard-to-machine materials. To assess the performance of PRA single grain grinding and to investigate the underlying mechanisms, the finite element simulation software ABAQUS 6.14 was employed to model the grinding of Ti6Al4V titanium alloy with a single diamond abrasive grain. The dependence of grinding force and temperature in single grain grinding with a PRA or an NRA under different grinding parameters was studied and compared. PRA and NRA single diamond grain grinding experiments on Ti6Al4V alloy were carried out, with grinding forces measured using a dynamometer and compared with the simulation results. The grinding surface morphology and surface roughness were observed and measured, and a comparison was made between PRA and NRA grinding. The results indicated that in single diamond grain grinding, transforming to a PRA significantly enhances grinding performance, as evidenced by reduced grinding forces, lower temperatures, improved surface morphology, and decreased surface roughness. These findings suggest that PRA single diamond grain grinding offers substantial benefits for the precision machining of hard-to-machine materials, marking a step forward in optimizing surface finishes. Full article
(This article belongs to the Special Issue New Advances in Precision Machining)
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15 pages, 4483 KiB  
Article
Selected Aspects of Precision Machining on CNC Machine Tools
by Jozef Peterka, Marcel Kuruc, Vitalii Kolesnyk, Ivan Dehtiarov, Jana Moravcikova, Tomas Vopat, Peter Pokorny, Frantisek Jurina and Vladimir Simna
Machines 2023, 11(10), 946; https://doi.org/10.3390/machines11100946 - 10 Oct 2023
Cited by 3 | Viewed by 2130
Abstract
The work is new due to the type of process used—ultrasonic precision machining—to determine the possible effect of spindle heating (long-term machining) on the precision of the flat surface. It was carried out on a precise ultrasonic machining machine, and the material of [...] Read more.
The work is new due to the type of process used—ultrasonic precision machining—to determine the possible effect of spindle heating (long-term machining) on the precision of the flat surface. It was carried out on a precise ultrasonic machining machine, and the material of workpiece was ceramic Al2O3. A flat surface was machined. Such an experiment has not been feasible until now. The experiment was divided into two days. On the first day, the machining time was 4 h. It is a long enough time to create a temperature-steady state. On the second day, with a cold tool and cold machine tool, we continued where we left off on the first day. This is how we monitored the accuracy of the dimensions of the workpiece on the plane surface. We have achieved the following: The average interface depth achieved values of 0.007089 mm and 0.003667 mm for cold and heated spindles, respectively. It means that when the spindle is not heated, the depth of the interface is higher by 93% (almost double the depth). The average standard deviation of the interface depth is 0.001683 mm and 0.000997 mm for cold and heated spindles, respectively. It means that when the spindle is not heated, the process is not as stable, and the standard deviation is higher by 69%. Full article
(This article belongs to the Special Issue New Advances in Precision Machining)
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14 pages, 4498 KiB  
Article
The Transverse Vibration Characteristics of Circular Saw Blade on Mobile Cantilever-Type CNC Sawing Machine
by Xinyu Yan, Yunqi Cui, Hongru Qiu, Tao Ding, Nanfeng Zhu and Baojin Wang
Machines 2023, 11(5), 549; https://doi.org/10.3390/machines11050549 - 12 May 2023
Cited by 2 | Viewed by 2230
Abstract
A circular saw blade is a commonly used tool in wood processing. The transverse vibration of the saw blade plays an important role in processing quality during cutting and affects its service life as well. In the study, the transverse vibration of the [...] Read more.
A circular saw blade is a commonly used tool in wood processing. The transverse vibration of the saw blade plays an important role in processing quality during cutting and affects its service life as well. In the study, the transverse vibration of the circular saw blade was investigated at the constant rotation by the simulation using ANSYS software when changing the cantilever length of the cantilever woodworking CNC circular saw machine. Meanwhile, the transverse vibration of the circular saw blade without and with load was explored by the eddy current sensors for when the detection point was differently away from the center of the circular saw blade. The time domain, probability density distribution, and power spectrum characteristics of the transverse vibration signal were analyzed, and the simulation values were compared with the actual cutting data. The results revealed that under certain conditions, the maximum transverse vibration value of the circular saw blade was the smallest in the simulation, then the middle in no-load, and the largest in actual cutting. The maximum transverse vibration value of the saw blade was increased with the extension of the cantilevered overhang, but gradually and slightly, indicating the transverse vibration was hardly affected by the change in overhang length of less than 300 mm. The finding provides the reference for the structural optimization design of cantilever CNC circular saw machines and the promotion of its application. Full article
(This article belongs to the Special Issue New Advances in Precision Machining)
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