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Metals
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Advances in Metal Cutting and Machining Processes
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Advances in Metal Cutting and Machining Processes

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Structural Integrity of Metals".

Deadline for manuscript submissions: 30 April 2025 | Viewed by 3361

Special Issue Editor

Dr. Nikolaos A. Fountas

E-Mail Website
Guest Editor
Laboratory of Manufacturing Processes and Machine Tools (LMProMaT), Department of Mechanical Engineering Educators, School of Pedagogical and Technological Education (ASPETE), GR 151 22 Amarousion, Greece
Interests: intelligent manufacturing; machinability of materials; optimization methodologies; CNC machining; CAD/CAM/CAE systems

Special Issue Information

Dear Colleagues,

Machining processes are integral parts of industrial production and play a pivotal role in the manufacturing of versatile, aesthetic, reliable, and durable products. Future trends have imposed the need to develop and implement eco-friendly manufacturing operations and energy-efficient technologies while ensuring sustainability and high quality. The different machining processes adhere to important principles that are still investigated by researchers worldwide and involve a significant number of technological parameters as well as constraints. Recent achievements in product design, process modeling and simulation, materials science, and CNC programming/control have led to remarkable enhancements in efficiency, quality, and flexibility.

This Special Issue aims to provide a reference for the exchange of scientific knowledge related to machining processes, recent technological advances, and the high-quality research attributes of modern manufacturing technology. By collecting and highlighting a diverse body of dignified contributions, this Special Issue will present an in-depth understanding of the latest research aspects regarding manufacturing automation, machine intelligence, hybrid manufacturing, machinability of materials, and machining process sustainability.

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

CNC machine tools; machining strategies optimization; advances in conventional and nonconventional material removal operations; software integration; precision machining; and surface integrity.

Dr. Nikolaos A. Fountas
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. 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

  • metal cutting
  • machining intelligence
  • surface quality
  • hybrid manufacturing
  • machining strategies
  • machinability
  • machining optimization
  • process modeling

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  • Ease of navigation: Grouping papers by topic helps scholars navigate broad scope journals more efficiently.
  • Greater discoverability: Special Issues support the reach and impact of scientific research. Articles in Special Issues are more discoverable and cited more frequently.
  • Expansion of research network: Special Issues facilitate connections among authors, fostering scientific collaborations.
  • External promotion: Articles in Special Issues are often promoted through the journal's social media, increasing their visibility.
  • e-Book format: Special Issues with more than 10 articles can be published as dedicated e-books, ensuring wide and rapid dissemination.

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

Published Papers (3 papers)

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Research

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14 pages, 5473 KiB  
Article
A Novel Design Method for Chip Flute of Indexable Insert Drill Used at Large Drilling Depth
by Aisheng Jiang, Zhanqiang Liu and Jinfu Zhao
Metals 2024, 14(12), 1351; https://doi.org/10.3390/met14121351 - 27 Nov 2024
Viewed by 758
Abstract
The design of the chip flute in indexable insert drills significantly influences chip removal efficiency, drill diameter deflection, and drill deformation in the metal drilling process, which are crucial for maintaining drill stability and minimizing deviations in the diameter of the drilled hole. [...] Read more.
The design of the chip flute in indexable insert drills significantly influences chip removal efficiency, drill diameter deflection, and drill deformation in the metal drilling process, which are crucial for maintaining drill stability and minimizing deviations in the diameter of the drilled hole. However, traditional chip flute designs fail to meet production standards when drilling deep holes in 42CrMo, particularly at depths reaching up to seven times the hole diameter. This study introduces an innovative optimization method for the chip flute design of indexable insert drills specifically intended for metal deep-cutting applications, which involves refining both the cross-sectional and circumferential profiles of the chip flute. A novel combined cross-section for the chip flute was developed and tested against the conventional double U-profile in drilling experiments on 42CrMo. Based on the chip shape of the inner and outer inserts, the inner insert flute section is designed into a U-shaped section and the outer insert flute section is designed into trapezoidal section, respectively, so as to increase the proportion of the effective chip removal area in the chip flute, which reduces the chip flute section area and increases the core thickness of the tool holder. Additionally, the circumferential profile was enhanced through orthogonal simulation experiments. The findings revealed that the drill diameter deflection using the newly designed combined cross-section was reduced by 21.76% compared to the traditional double U-profile in the metal drilling process. The indexable insert drill featuring this optimized chip flute configuration exhibited significant improvements in the drill diameter deflection, drill deformation, and drilled hole diameter accuracy, outperforming the standard drill design. Full article
(This article belongs to the Special Issue Advances in Metal Cutting and Machining Processes)
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14 pages, 29305 KiB  
Article
A Comparative Study on Laser Cutting Performance with Varying Speeds at 10 M Underwater
by Danbi Song, Jungsoo Choi, Sujin Lee, Ryoonhan Kim and Induck Park
Metals 2024, 14(11), 1270; https://doi.org/10.3390/met14111270 - 8 Nov 2024
Viewed by 1064
Abstract
Despite the dismantling structures that are submerged to significant depths of water during the decommissioning of nuclear power plants, there is limited research on deep-water laser cutting processes. A self-designed pressurized chamber was used in this study and successfully conducted the world’s first [...] Read more.
Despite the dismantling structures that are submerged to significant depths of water during the decommissioning of nuclear power plants, there is limited research on deep-water laser cutting processes. A self-designed pressurized chamber was used in this study and successfully conducted the world’s first laser cutting experiment in a simulated 10 m water depth environment. laser cutting was performed in a 10 m underwater environment, and the cutting efficiency was compared to that observed in a 1 m underwater environment. Therefore, A 100 mm thickness of 304 stainless steel was successfully cut underwater, and the highest cutting speed of 100 mm/min was achieved. The result indicates that, as the cutting speed increased during underwater laser cutting, both the heat input and the mass flow rate of the assist gas decreased, resulting in a narrower rear kerf width and an ineffective evacuation of the molten metal. Full article
(This article belongs to the Special Issue Advances in Metal Cutting and Machining Processes)
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Review

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22 pages, 5181 KiB  
Review
Laser Surface Texturing of Cutting Tools for Improving the Machining of Ti6Al4V: A Review
by Javier Garcia-Fernandez, Jorge Salguero, Moises Batista, Juan Manuel Vazquez-Martinez and Irene Del Sol
Metals 2024, 14(12), 1422; https://doi.org/10.3390/met14121422 - 12 Dec 2024
Cited by 1 | Viewed by 1098
Abstract
The machining of titanium alloys, particularly Ti6Al4V, presents a significant challenge in manufacturing engineering. Its high strength, low thermal conductivity and high chemical reactivity make Ti6Al4V a hard-to-machine material. However, the machining process is critical for aerospace and biomedical industries. The rapid wear [...] Read more.
The machining of titanium alloys, particularly Ti6Al4V, presents a significant challenge in manufacturing engineering. Its high strength, low thermal conductivity and high chemical reactivity make Ti6Al4V a hard-to-machine material. However, the machining process is critical for aerospace and biomedical industries. The rapid wear and short lifetime of cutting tools are the main limitations in Ti6Al4V machining, leading to a large increase in manufacturing costs and compromising the surface quality of machined components. Faced with this problem, the texturing of cutting tools, especially through laser-based techniques, has gained considerable attention in the last decade due to improvement of the tribological properties of textured surfaces. Laser Surface Texturing (LST) has emerged as a promising technique to improve the tribological performance of cutting tools by enabling the creation of precise surface structures. Building on prior research, this review provides a comprehensive overview of the most recent research on this topic, summarizing key findings and outcomes from various investigations. Full article
(This article belongs to the Special Issue Advances in Metal Cutting and Machining Processes)
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