Analytical Modeling of Advanced Manufacturing Processes

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

Deadline for manuscript submissions: closed (30 June 2022) | Viewed by 2694

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Guest Editor
Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332, USA
Interests: ultrasonic-vibration-assisted milling; laser-assisted milling
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Dear Colleagues,

The control of machining is critical to the quality of the final product, while the evaluation of advanced manufacturing processes becomes more challenging. The performance of machining can be evaluated through several aspects. In situ parameters including force, temperature, and tool wear indicate whether the machining is conducted within an allowable range of equipment. Force and temperature in shear zone are the results of both mechanical and thermal loads. Moreover, tool wear describes the gradual failure of cutting tools due to regular operation. Residual stress and surface roughness reflect the machining process and are directly related to the fatigue performance and surface quality of the product. Surface roughness characterizes the surface texture in terms of deviations. Residual stress is created under mechanical load, thermal gradient, and phase change, which significantly affects the damage tolerance and fatigue performance of the product.

To date, most related studies have been carried out using numerical analysis or experimental investigation. The analytical approach is able to reveal the physics nature in the process within a short computation time. This includes forward analysis by predicting machining parameters (force, temperature, etc.) under given conditions and inverse analysis by predicting machining conditions under desired parameters.

For this Special Issue in Metals, we welcome reviews and articles regarding analytical modeling of various parameters in advanced manufacturing processes.

Dr. Yixuan Feng
Guest Editor

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Keywords

  • Analytical modeling
  • Advanced manufacturing
  • Machining force
  • Machining temperature
  • Tool wear
  • Residual stress
  • Surface roughness
  • Surface hardness
  • Microstructure evolution
  • Inverse analysis

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Published Papers (1 paper)

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Research

22 pages, 7196 KiB  
Article
Analytical Model for Temperature Prediction in Milling AISI D2 with Minimum Quantity Lubrication
by Linger Cai, Yixuan Feng, Yu-Ting Lu, Yu-Fu Lin, Tsung-Pin Hung, Fu-Chuan Hsu and Steven Y. Liang
Metals 2022, 12(4), 697; https://doi.org/10.3390/met12040697 - 18 Apr 2022
Cited by 9 | Viewed by 1829
Abstract
Milling with minimum quantity lubrication (MQL) is now a commonly used machining technique in industry. The application of the MQL significantly reduces the temperature on the machined surface, while the cost of the lubricants is limited and the pollution caused by the lubricants [...] Read more.
Milling with minimum quantity lubrication (MQL) is now a commonly used machining technique in industry. The application of the MQL significantly reduces the temperature on the machined surface, while the cost of the lubricants is limited and the pollution caused by the lubricants is better controlled. However, the fast prediction of the milling temperature during the process has not been well developed. This paper proposes an analytical model for milling temperature prediction at the workpiece flank surface with MQL application. Based on the modified orthogonal cutting model and boundary layer lubrication effect, the proposed model takes in the process parameters and can generate the temperature profile at the workpiece surface within 1 min. The model is validated with experimental data in milling AISI D2 steel. With an average absolute error of 10.38%, the proposed model provides a reasonable temperature prediction compared to the experimental results. Based on the proposed model, this paper also investigates the effect of different cutting parameters on the cutting temperature. It is found that the application of the MQL decreases the temperature at the cutting zone, especially at the flank surface of the workpiece, which is due to the heat loss led by air-oil flow. Full article
(This article belongs to the Special Issue Analytical Modeling of Advanced Manufacturing Processes)
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