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Advanced Machining Technology for Modern Engineering Materials (2nd Edition)
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Advanced Machining Technology for Modern Engineering Materials (2nd Edition)

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 September 2024 | Viewed by 4340

Special Issue Editors

Dr. Muthuramalingam Thangaraj

E-Mail Website
Guest Editor
Department of Mechatronics Engineering, SRM Institute of Science and Technology, Kattankulathur Campus, Chennai 603203, Tamilnadu, India
Interests: mechatronics; unconventional machining; optimization; manufacturing automation; printed electronics
Special Issues, Collections and Topics in MDPI journals
Dr. Beata Leszczyńska-Madej

E-Mail Website
Guest Editor
Department of Materials Science and Non-Ferrous Metals Engineering, Faculty of Non-Ferrous Metals, AGH University of Science and Technology, 30-059 Cracow, Poland
Interests: microstructure characterization; materials science; friction stir processes; tribology; metal-matrix composites (MMCs); powder metallurgy; severe plastic deformation (SPD); light metals and alloys; surface engineering; bearing alloys
Special Issues, Collections and Topics in MDPI journals
Dr. Angelos P. Markopoulos

E-Mail Website
Guest Editor
Section of Manufacturing Technology, School of Mechanical Engineering, National Technical University of Athens, 15780 Athens, Greece
Interests: manufacturing technology; machining processes; non-conventional machining; modeling and simulation
Special Issues, Collections and Topics in MDPI journals
Dr. Panagiotis Karmiris-Obratański

E-Mail Website
Guest Editor
Department of Manufacturing Systems, Faculty of Mechanical Engineering and Robotics, AGH University of Science and Technology, 30-059 Cracow, Poland
Interests: metal cutting and cutting tools; non-conventional machining; surface topography; surface metrology; materials science; optimization of process parameters; friction stir processes; additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Advances in material science have given an unprecedented boost in engineering. Materials with exceptional properties (mechanical, thermal, and chemical) have been developed, including super and memory alloys, composite materials, and biocompatible materials. At the same time, the machining industry must follow these advances, coming up with new machining methods and processes, as well as effective ways of studying those materials at the macro-, meso-, and microscale. Therefore, the current Special Issue aims to provide a forum for scientists’ research on the machinability and the mechanical properties of advanced materials. We will host experimental and/or computational studies concerning conventional, non-conventional, and hybrid machining, and additive methods of advanced materials. Additionally, research about advanced techniques in the study of materials, which give an inside view and a better understanding of the fundamental mechanisms, are welcome. Finally, review articles about the topics mentioned above are encouraged.

Dr. Muthuramalingam Thangaraj
Dr. Beata Leszczyńska-Madej
Dr. Angelos P. Markopoulos
Dr. Panagiotis Karmiris-Obratański
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. Materials 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 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

  • nanomaterials/nanocomposites
  • laser processing/laser-assisted machining
  • ultrasonic machining
  • friction stir processing/welding
  • microstructure modeling
  • multiscale modeling
  • optimization
  • hydrogen embrittlement
  • additive manufacturing
  • polymers and leather
  • surface texture/topography

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Related Special Issue

Published Papers (5 papers)

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Research

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19 pages, 6178 KiB  
Article
Impact of Toolpath Pitch Distance on Cutting Tool Nose Radius Deviation and Surface Quality of AISI D3 Steel Using Precision Measurement Techniques
by Santhakumar Jayakumar, Sathish Kannan and U. Mohammed Iqbal
Materials 2024, 17(18), 4519; https://doi.org/10.3390/ma17184519 (registering DOI) - 14 Sep 2024
Abstract
The selection of the right tool path trajectory and the corresponding machining parameters for end milling is a challenge in mold and die industries. Subsequently, the selection of appropriate tool path parameters can reduce overall machining time, improve the surface finish of the [...] Read more.
The selection of the right tool path trajectory and the corresponding machining parameters for end milling is a challenge in mold and die industries. Subsequently, the selection of appropriate tool path parameters can reduce overall machining time, improve the surface finish of the workpiece, extend tool life, reduce overall cost, and improve productivity. This work aims to establish the performance of end milling process parameters and the impact of trochoidal toolpath parameters on the surface finish of AISI D3 steel. It especially focuses on the effect of the tool tip nose radius deviation on the surface quality using precision measurement techniques. The experimental design was carried out in a systematic manner using a face-centered central composite design (FCCD) within the framework of response surface methodology (RSM). Twenty different experiment trials were conducted by changing the independent variables, such as cutting speed, feed rate, and trochoidal pitch distance. The main effects and the interactions of these parameters were determined using analysis of variance (ANOVA). The optimal conditions were identified using a multiple objective optimization method based on desirability function analysis (DFA). The developed empirical models showed statistical significance with the best process parameters, which include a feed rate of 0.05 m/tooth, a trochoidal pitch distance of 1.8 mm, and a cutting speed of 78 m/min. Further, as the trochoidal pitch distance increased, variations in the tool tip cutting edge were observed on the machined surface due to peeling off of the coating layer. The flaws on the tool tip, which alter the edge micro-geometry after machining, resulted in up to 33.83% variation in the initial nose radius. Deviations of 4.25% and 5.31% were noted between actual and predicted values of surface roughness and the nose radius, respectively. Full article
(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials (2nd Edition))
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24 pages, 9406 KiB  
Article
An Investigation of the Effect of Novel Mono/Bi-Layered PVD-Coated WC Tools on the Machinability of Ti-5Al-5V-5Mo-3Cr
by Hasan S. Syed, Jose M. DePaiva, Victor Saciotto and Stephen C. Veldhuis
Materials 2024, 17(15), 3743; https://doi.org/10.3390/ma17153743 - 28 Jul 2024
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Abstract
The Ti-5Al-5V-5Mo-3Cr (Ti-5553) alloy is a relatively novel difficult-to-cut material with limited machinability and tool life analysis available in the literature, and hence requires further investigation. This study focuses on the machining and tribological performance of Ti-5553 under high-speed finish turning (150 m/min, [...] Read more.
The Ti-5Al-5V-5Mo-3Cr (Ti-5553) alloy is a relatively novel difficult-to-cut material with limited machinability and tool life analysis available in the literature, and hence requires further investigation. This study focuses on the machining and tribological performance of Ti-5553 under high-speed finish turning (150 m/min, 175 m/min, and 200 m/min) via novel mono/bi-layered PVD-coated WC tools. A base AlTiN coating is used as the reference monolayer coating, with AlCrN, diamond-like ta-C, and TiAlSiN coatings each deposited on top of a base AlTiN coating, totaling four separate coated tools (one monolayer and three bi-layer). Tool life, cutting forces, workpiece surface quality, and tribological chip analysis are among the subjects of investigation in this study. Overall, the AlTiN/AlCrN coated tool outperformed all the other combinations: an improvement of ~19% in terms of tool life in reference to the base AlTiN coating when averaging across the three speeds; lowest surface roughness values: ~0.30, 0.33, and 0.64 µm; as well as the lowest chip back surface roughness values: ~0.80, 0.68, and 0.81 µm at 150, 175, and 200 m/min, respectively. These results indicate that the AlTiN/AlCrN coating is an excellent candidate for industrial applications involving high-speed machining of Ti-5553. Full article
(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials (2nd Edition))
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19 pages, 4973 KiB  
Article
Understanding the Relationship between Surface Quality and Chip Morphology under Sustainable Cutting Environments
by Mustafa Günay and Mehmet Erdi Korkmaz
Materials 2024, 17(8), 1826; https://doi.org/10.3390/ma17081826 - 16 Apr 2024
Cited by 2 | Viewed by 846
Abstract
Although chip morphology changes according to the machining method and related cutting parameters, chip formation affects the quality of the machined surface. In this context, it is very important to understand the relationship between chip morphology and surface quality, especially in materials that [...] Read more.
Although chip morphology changes according to the machining method and related cutting parameters, chip formation affects the quality of the machined surface. In this context, it is very important to understand the relationship between chip morphology and surface quality, especially in materials that are difficult to machine. In the presented study, the changes in chip morphology, surface morphology, and surface quality criteria (Ra and Rz) that occurred during the milling of precipitation-hardened steel in different cutting environments were analyzed. Milling experiments were carried out in dry, MQL (minimum quantity lubrication), nano-MQL (graphene), nano-MQL (hBN), Cryo, and Cryo-MQL environments using TiAlN-coated inserts and three different cutting speeds and feed rates. While the highest values in terms of Ra and Rz were measured in dry machining, the minimum values were obtained in a nano-MQL (hBN) cutting environment. Due to the lubrication and low friction provided by the MQL cutting environment, chips were formed in thinner segmented forms. This formation reduced the chip curve radius and thus provided a more stable surface morphology. On the other hand, Cryo-ambient gas could not effectively leak into the cutting zone due to the intermittent cutting process, but it increased the brittleness of the chips with the cooling effect and provided a similar surface morphology. The values of minimum Ra and Rz were obtained as 0.304 mm and 1.825 mm, respectively, at a 60 m/min cutting speed and 0.04 mm/rev feed. Consequently, the use of nano-MQL cutting medium is seriously recommended in terms of surface quality in milling operations of difficult-to-machine materials. Full article
(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials (2nd Edition))
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21 pages, 5250 KiB  
Article
Investigation of the Influence of Machining Parameters and Surface Roughness on the Wettability of the Al6082 Surfaces Produced with WEDM
by Dimitrios Skondras-Giousios, Panagiotis Karmiris-Obratański, Magdalena Jarosz and Angelos P. Markopoulos
Materials 2024, 17(7), 1689; https://doi.org/10.3390/ma17071689 - 7 Apr 2024
Viewed by 885
Abstract
Electrical Discharge Machining (EDM) is a non-conventional machining technique, capable of processing any kind of conductive material. Recently, it has been successfully utilized for producing hydrophobic characteristics in inherently hydrophilic metallic materials. In this work, Wire Electrical Discharge Machining (WEDM) was utilized for [...] Read more.
Electrical Discharge Machining (EDM) is a non-conventional machining technique, capable of processing any kind of conductive material. Recently, it has been successfully utilized for producing hydrophobic characteristics in inherently hydrophilic metallic materials. In this work, Wire Electrical Discharge Machining (WEDM) was utilized for producing hydrophobic characteristics on the surface of the aluminum alloy 6082, and various parameters that can affect wettability were investigated. Adopting an orthogonal Taguchi approach, the effects of the process parameter values of peak current, pulse-on time, and gap voltage on the contact angles of the machined surfaces were investigated. After machining, all samples were observed to have obtained hydrophobic properties, reaching contact angles up to 132°. The peak current was identified as the most influential parameter regarding the contact angle, while the gap voltage was the less influential parameter. A contact angle variation of 30° was observed throughout different combinations of machining parameters. Each combination of the machining parameters resulted in a distinct surface morphology. The samples with moderate roughness values (3.4 μm > Sa > 5.7 μm) were found to be more hydrophobic than the samples with high or low values, where the contact angle was measured under 115°. In addition, the finite element modeling of the experimental setup, with parametric surfaces of uniform random and Perlin noise types of roughness, was implemented. Time dependent simulations coupling phase field and laminar flow for the modelingof the wetting of surfaces with different surface roughness characteristics showed that an increase in the Sa roughness and total wetted area can lead to an increase in the contact angle. The combination of experimental and computational results suggests that the complexity of the wettability outcomes of aluminum alloy surfaces processed with WEDM lies in the interplay between variations of the surface chemical composition, roughness, micro/nano morphology, and the surface capability of forming a composite air/water interface. Full article
(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials (2nd Edition))
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Review

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22 pages, 9923 KiB  
Review
A State of the Art on Cryogenic Cooling and Its Applications in the Machining of Difficult-to-Machine Alloys
by Mehmet Erdi Korkmaz and Munish Kumar Gupta
Materials 2024, 17(9), 2057; https://doi.org/10.3390/ma17092057 - 27 Apr 2024
Cited by 2 | Viewed by 1075
Abstract
Cryogenic cooling has gathered significant attention in the manufacturing industry. There are inherent difficulties in machining materials that are difficult to machine because of high levels of hardness, abrasiveness, and heat conductivity. Increased tool wear, diminished surface finish, and reduced machining efficiency are [...] Read more.
Cryogenic cooling has gathered significant attention in the manufacturing industry. There are inherent difficulties in machining materials that are difficult to machine because of high levels of hardness, abrasiveness, and heat conductivity. Increased tool wear, diminished surface finish, and reduced machining efficiency are the results of these problems, and traditional cooling solutions are insufficient to resolve them. The application of cryogenic cooling involves the use of extremely low temperatures, typically achieved by employing liquid nitrogen or other cryogenic fluids. This study reviews the current state of cryogenic cooling technology and its use in machining difficult-to-machine materials. In addition, this review encompasses a thorough examination of cryogenic cooling techniques, including their principles, mechanisms, and effects on machining performance. The recent literature was used to discuss difficult-to-machine materials and their machining properties. The role of cryogenic cooling in machining difficult materials was then discussed. Finally, the latest technologies and methods involved in cryogenic cooling condition were discussed in detail. The outcome demonstrated that the exploration of cryogenic cooling methods has gained prominence in the manufacturing industry due to their potential to address challenges associated with the machining of exotic alloys. Full article
(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials (2nd Edition))
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