Numerical and Experimental Advances in Metal Processing, 2nd Edition

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: 31 July 2026 | Viewed by 642

Special Issue Editors


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Guest Editor
Department of Mechanical Engineering, Faculty of Engineering, University of Porto, 4200-465 Porto, Portugal
Interests: manufacturing processes; simulation; fracture mechanics
Special Issues, Collections and Topics in MDPI journals

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Faculty of Engineering, University of Porto, 4200-465 Porto, Portugal
Interests: manufacturing processes; metal forming technology and processing; sheet metal forming; numerical simulation; experimental validation; material testing and constitutive modelling
Special Issues, Collections and Topics in MDPI journals

E-Mail Website
Guest Editor
Institute of Science and Innovation in Mechanical and Industrial Engineering, R. Dr. Roberto Frias, 400, 4200-465 Porto, Portugal
Interests: metal forming processes; material characterization; constitutive modelling; numerical simulation; experimental validation; inverse optimization techniques
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue aims to present the most recent advances in the manufacturing processes of metallic materials and to identify directions both in experimental and numerical research, including the requirements for sustainable technologies and processes.

The covered topics will be of major interest for scientists and professionals working at universities, research institutes, laboratories and industries concerned with established and novel manufacturing methodologies using conventional and emerging materials.

A key aspect is proper process design in order to guarantee the compliance of the final product with the intended functionality, while at the same time minimizing resource usage. Metal processing optimization and the strength of the final products, including their fatigue performance, could be anticipated at the design stage by resorting to advanced modeling, including numerical simulation (e.g., FEA). The continuous development of these technologies and processes, research on suitable numerical tools and models, and experimental procedures allow proper process design for tailored product performance, which is mandatory for industry competitiveness and the sustainability of society.

The Special Issue will cover, but will not be limited to, the following topics:

  • Formability in metal forming processes;
  • Modeling and designing of forming and joining processes;
  • Ductile damage and fracture: experiments, modeling and numerical prediction;
  • Modeling of anisotropic behavior in plasticity;
  • Inverse identification of constitutive material models;
  • Additive, subtractive and hybrid manufacturing;
  • Emerging manufacturing processes;
  • Intelligent metal processing technologies.
  • Processes of lightweight metals and numerical modeling;
  • Product design and process optimization;
  • Mechanical performance of products.

Dr. Abílio M. P. De Jesus
Dr. Abel Dias dos Santos
Dr. Rui L. Amaral
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 250 words) can be sent to the Editorial Office for assessment.

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

  • manufacturing
  • metals
  • manufacturing processes
  • fatigue
  • fracture
  • product design
  • finite element analysis
  • structural integrity
  • surface integrity
  • residual stresses

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Published Papers (1 paper)

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Research

14 pages, 4680 KB  
Article
Performance Evaluation of Five-Axis CNC Milling via Spindle Current and Vibration Monitoring
by Beatriz Cardoso, José Ferreira, Tiago E. F. Silva, Pedro Sá Couto, Ana Reis and Abílio M. P. de Jesus
Metals 2026, 16(1), 129; https://doi.org/10.3390/met16010129 - 22 Jan 2026
Viewed by 423
Abstract
The digitalization of machining processes is increasingly recognized as essential for achieving higher productivity, reliability, and traceability. However, access to reliable in-process sensor data remains limited, particularly in multi-axis CNC machining, where dimensional accuracy and surface integrity strongly depend on stable and optimized [...] Read more.
The digitalization of machining processes is increasingly recognized as essential for achieving higher productivity, reliability, and traceability. However, access to reliable in-process sensor data remains limited, particularly in multi-axis CNC machining, where dimensional accuracy and surface integrity strongly depend on stable and optimized process conditions. This study investigates sensor-based monitoring as a practical approach for evaluating process performance in five-axis CNC milling. Electric current and vibration signals were acquired during three machining operations, under distinct cutting parameters, using current clamps and a plug-and-play MEMS accelerometer. The signals were processed using the root mean square method to assess the correlation between sensor data and machining conditions. Dimensional inspection of each workpiece was carried out to verify geometric conformity. The results show that spindle current measurements exhibit a strong linear correlation with material removal rate and cutting power, supporting their use as indicators of cutting forces and energy consumption. Vibration signals revealed pronounced dynamic behaviour for specific tool orientations, particularly in transverse to tool axis direction. The proposed methodology provides a simple and low-cost framework for integrating sensor-based monitoring into five-axis CNC milling, particularly relevant for semi-roughing operations, and offers a basis for future studies on process optimization and real-time condition monitoring. Full article
(This article belongs to the Special Issue Numerical and Experimental Advances in Metal Processing, 2nd Edition)
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