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High-Performance Machining Processes: From Mechanisms to Equipment

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A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (31 October 2023) | Viewed by 21042

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Special Issue Editors

Prof. Dr. Jun Zhang

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Guest Editor

State Key Laboratory for Manufacturing Systems Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, China
Interests: high-performance machining; machining mechanisms; machining dynamics; surface integrity; process monitoring

Prof. Dr. Kuo Liu

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Guest Editor

Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian 116024, China
Interests: high-performance machine tools; cryogenic machining; intelligent machining
Special Issues, Collections and Topics in MDPI journals

Dr. Hongguang Liu

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Guest Editor

State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an 710049, China
Interests: numerical modeling; material removal processes; surface integrity; cryogenic machining; difficult-to-cut materials
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The concept of high-performance machining integrates several important factors, including high productivity, high surface quality and long tool-life into a unique evaluation system, which is extremely interesting to the machining community. To reach this goal, requirements related to two aspects should be satisfied: 1) to understand the mechanisms behind material removal in order to optimize cutting parameters and obtain high-quality products; and 2) to develop reliable equipment toward stable machining conditions in order to provide high productivity and quality. Both aspects are essential for the final outputs. Although plenty of work has been done in this area, some matters are still unclear. Especially following the rapid development and application of new materials and technologies in production, some new challenges have also appeared. Therefore, more efforts should be devoted to exploring the in-depth mechanisms of machining processes and developing advanced equipment to meet the rapidly increasing demands.

This Special Issue aims to provide original research on high-performance machining processes, toward promoting the in-depth understanding of machining mechanisms and helping to develop novel equipment. Research areas may include (but are not limited to) the following:

Conventional and non-conventional machining processes;
Machining of difficult-to-cut materials;
Material removal mechanisms and surface integrity;
Tool wear mechanisms;
Design of cutting tools;
Machine tool dynamics and machining dynamics;
Machine tool design and precision control;
Adaptive control and process monitoring of machining processes;
Precision retention of machining equipment.

Prof. Dr. Jun Zhang
Prof. Dr. Kuo Liu
Dr. Hongguang Liu
Guest Editors

Manuscript Submission Information

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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. Processes is an international peer-reviewed open access monthly journal published by MDPI.

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Keywords

high-performance machining
machining mechanisms
difficult-to-cut materials
surface integrity
tool wear
machine tool
dynamics
process monitoring
precision machining

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Published Papers (11 papers)

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Research

16 pages, 8836 KiB

Open AccessArticle

Test and Analysis of the Heat Dissipation Effect of the Spindle Heat Conductive Path Based on the IPTO Algorithm

by Yang Li, Zhongting Liu, Lei Li, Jingyao Tian, Zhaoyang Hou, Wanhua Zhao and Wenwu Wu

Processes 2024, 12(1), 4; https://doi.org/10.3390/pr12010004 - 19 Dec 2023

Viewed by 839

Abstract

In this paper, in order to reduce the spindle temperature rise and enhance the spindle heat dissipation capability, a top complementary heat conductive path of the spindle based on the IPTO algorithm was designed. In order to verify the heat dissipation effect of the heat conductive path, an experimental test platform was constructed. Experiments on the thermal characteristics of water-cooled and air-cooled heat conductive paths with different volume proportions were conducted to test the temperature rise of the spindle and analyze the effect of the heat conductive path with different volume proportions on the temperature distribution of the spindle. The heat conductive path with the optimal volume proportion was determined and the heat dissipation effect of the heat conductive path was verified. Full article

(This article belongs to the Special Issue High-Performance Machining Processes: From Mechanisms to Equipment)

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22 pages, 10056 KiB

Open AccessArticle

Enhancing Electric Discharge Machining Performance by Selecting Electrode Design and Geometrical Parameters for Square, Triangular, and Hexagonal Profiled Holes

by Madiha Rafaqat, Nadeem Ahmad Mufti, Muhammad Qaiser Saleem, Naveed Ahmed, Ateekh Ur Rehman, Sadaf Zahoor and Muhammad Asad Ali

Processes 2023, 11(9), 2661; https://doi.org/10.3390/pr11092661 - 5 Sep 2023

Cited by 2 | Viewed by 1171

Abstract

Manufacturing of dies, molds, and their allied components requires the machining of holes with different profiles. Electric discharge machining (EDM) die-sinking is a crucial process used in the dies and molds manufacturing industry. By nature, EDM die-sinking is a relatively slow process in terms of material removal rate (MRR) and there are high amounts of tool material loss in terms of tool wear rate (TWR) which directly influence dimensional accuracies and surface roughness (SR). Therefore, the process is continuously evolving to address these limitations. The present research is aligned in this direction such as to bring improvements in MRR, TWR, and SR through modifications to the conventional electrode design and its geometrical parameters. Traditional designs of EDM electrodes have a uniform cross-section through the tool’s entire length and have only one geometrical parameter, i.e., the tool’s cross-section. To improve the EDM performance, traditional designs are completely modified by introducing several geometrical parameters such as relief angles, land thickness, cross-sectional area, shank height, circular relief, and non-circular relief, etc. Electrode designs are employed to mill non-circular profiles including triangular, square, and hexagonal shaped holes. The EDM performance measures strongly depend on the tool’s geometrical parameters (design type, relief angle, land thickness), machining profile (circular, square, triangle, hexagon), as well as the height/depth of the machining feature. By selecting proper tool designs and corresponding geometrical parameters, the EDM performance measures can be improved significantly. Full article

(This article belongs to the Special Issue High-Performance Machining Processes: From Mechanisms to Equipment)

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15 pages, 7180 KiB

Open AccessArticle

Study on Enhanced Heat Transfer of the Convex Columns in the Cooling Channel of Motorized Spindle Based on Field Synergy

by Yang Li, Zhe Nie, Dongxu Su, Jingyao Tian, Wenlei He and Wanhua Zhao

Processes 2023, 11(8), 2431; https://doi.org/10.3390/pr11082431 - 12 Aug 2023

Viewed by 928

Abstract

The cooling performance of motorized spindles plays an important role in accuracy in high-speed machining. Aiming at improving the cooling performance of traditional motorized spindles, convex columns were built in the cooling channel. Based on field synergy, the effects of quadrilateral, circular and triangular convex columns on the heat transfer performance of the cooling channel were analyzed numerically. We also compared the pressure drop between the inlet and outlet under the same conditions. The results show that the cooling channels with triangular convex columns provide the best cooling effect with the smallest increase in area compared to quadrilateral convex columns and circular convex columns. The pressure drop in the cooling channels with a circular convex column is minimized. By optimizing the spacing of the convex column, the best effect was found at a spacing of 7 mm. By optimizing the angle of the top angle of the triangular column, it is found that the enhanced heat transfer effect is best at 120° when the heat transfer area is the same. In addition, when considering the addition of convex columns, it is important to ensure sufficient pressure drop to achieve a good cooling effect. Full article

(This article belongs to the Special Issue High-Performance Machining Processes: From Mechanisms to Equipment)

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22 pages, 9919 KiB

Open AccessArticle

Bearing Inner Ring Raceway Low-Temperature Aerosol Cooling Lubrication Grinding

by Zhou Chang and Lai Hu

Processes 2023, 11(5), 1546; https://doi.org/10.3390/pr11051546 - 18 May 2023

Viewed by 1433

Abstract

A low-temperature aerosol cooling and lubrication grinding test bench was built to evaluate the cooling and lubrication performance of the low-temperature aerosol. The mechanism of grinding residual stresses in the inner ring raceway under the coupling effect of grinding force and grinding heat was studied, and the effects of the grinding process parameters and cooling and lubrication conditions on the distribution state of the grinding residual stresses in the surface layer of the inner ring raceway were revealed. The results showed that reducing the initial temperature of the grinding fluid could reduce the residual tensile stresses on the raceway surface. The results also showed that the low-temperature aerosol cooling lubrication method is conducive to the generation of the axial residual compressive stress of −500 MPa and tangential residual compressive stress of −300 MPa in the inner ring raceway surface layer of the bearing. Compared with the convective heat transfer coefficient, the effect of the initial temperature of the grinding fluid is smaller. Full article

(This article belongs to the Special Issue High-Performance Machining Processes: From Mechanisms to Equipment)

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26 pages, 14220 KiB

Open AccessArticle

The Influence of Tool Geometry Parameters on Thermo-Mechanical Loads and Residual Stresses Induced by Orthogonal Cutting of AA6061-T6: A Numerical Investigation

by Sandrine A. Tcheuhebou Tina, Mahshad Javidikia, Mohammad Jahazi and Victor Songmene

Processes 2023, 11(4), 996; https://doi.org/10.3390/pr11040996 - 24 Mar 2023

Cited by 2 | Viewed by 1791

Abstract

The residual stresses state that a mechanical part obtained after machining is a crucial factor that impacts its in-service performance. This stress state is influenced by the thermomechanical loads exerted on the parts during the machining process, which are, in turn, determined by the tool parameters, process, and machining conditions. The aim of the present research was to anticipate how the cutting tool’s edge radius, rake angle, and clearance angle would affect the forces, temperature, and residual stresses induced while orthogonally cutting aluminum AA6061-T6. To achieve this, two-dimensional DEFORM™ software was utilized to develop a finite element model. The residual stresses trend results obtained demonstrated that rake angles of 0° and 17.5–20° values with a small edge radius (5 to 10 µm) and clearance angles of 7 and 17.5° values gave higher compressive stresses. The obtained simulated results were in good agreement with the experiments. The cutting forces, the temperature, and the maximum and minimum machining-induced residual stresses were found to be influenced more by the tool edge radius and the tool rake angle. The influence of the clearance angles on the above-mentioned machining responses was the least. Residual stresses can have a significant impact on the in-service performance of machined parts. The obtained results will help engineers select or design tools that promote a desired surface integrity during machining. This task is not obvious in practice because of difficulties in measuring residual stresses and also because the machining parameters and the tool geometry parameters have different and opposite impacts on thermo-mechanical loads, productivity, and on machining induced residual stresses. Full article

(This article belongs to the Special Issue High-Performance Machining Processes: From Mechanisms to Equipment)

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14 pages, 4628 KiB

Open AccessArticle

Variable-Coefficient Dynamic Modeling Method for a Ball Screw Feed System in the No-Extra-Load Running State

by Huijie Zhang, Jun Zha, Chao Du, Hui Liu, Yang Li and Dun Lv

Processes 2023, 11(3), 793; https://doi.org/10.3390/pr11030793 - 7 Mar 2023

Viewed by 1826

Abstract

In a ball screw feed system of high-speed/high-acceleration machine tools, large frictional and inertial forces may change the real contact state of the kinematic joints, resulting in changes in the contact and transmission stiffnesses and, hence, changes in the dynamic characteristics of the system. In this study, a variable–coefficient dynamic modeling method for a ball screw feed system is proposed, considering the influence of changes in the no-extra-load running states, such as position, speed, and acceleration. Based on Timoshenko beam elements with two nodes and four DOFs, an equivalent dynamic model of a ball screw feed system is established using the hybrid element method. The expression for the equivalent axial stiffness of individual kinematic joints is derived, considering the influence of the feed speed/acceleration under the no-extra-load running state of the system. In addition, the stiffness and mass of the screw shafts on both sides of the screw nut are calculated, considering the influence of the system’s feed position. Hence, we obtain the total stiffness and mass of the system in the no-extra-load running state and analyze the natural frequency. Finally, we conduct validation experiments on a ball screw feed system of a large gantry-type machine tool with different no-extra-load running states. Full article

(This article belongs to the Special Issue High-Performance Machining Processes: From Mechanisms to Equipment)

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22 pages, 10703 KiB

Open AccessArticle

One-Step High-Speed Finish Drilling of Inconel 718 Superalloy via Novel Inserts

by Saqib Anwar, Nauman Ahmad Khan, Sarmad Ali Khan and Syed Farhan Raza

Processes 2023, 11(3), 752; https://doi.org/10.3390/pr11030752 - 3 Mar 2023

Cited by 9 | Viewed by 2630

Abstract

Inconel 718 is considered the most widely adopted nickel-based superalloy, and drilling of this alloy is always challenging for researchers. Cemented carbide twist drills have been evaluated in the drilling of this alloy by changing the cutting environment or by varying the tool geometry. In the latter case, the cutting speed has been extended from 30 m/min to 60 m/min when drills are micro-textured or ground. In this study, contrary to cemented carbide twist drills, for the first time, inserts named stepped (central) and peripheral (wiper) are evaluated in the drilling of this alloy. The central insert is designed for balanced forces, while the peripheral is a wiper insert designed for better surface finish. Drilling experiments are conducted in flood cooling conditions with a 12 mm diameter twist drill equipped with novel stepped and wiper inserts at varying cutting speeds (25, 35, and 45 m/min) and feed rates (0.04, 0.06, and 0.08 mm/rev). At a cutting speed (Vc) of 25 m/min and feed rate (f) of 0.04 mm/rev, 25 holes are drilled with roughness (Ra) values ranging from 0.40 µm to 0.60 µm, which represents a significant increase in the number of holes per drill and improved surface finish over to previous work. The new inserts showed almost three-fold longer tool life compared to a standard drill bit at a higher Vc of 45 m/min and 0.04 mm/rev f with an Ra between 0.22 µm to 0.43 µm, which is deemed acceptable for aerospace applications. In addition, minimal surface and sub-surface defects were observed, eliminating the need for a post-drilling finishing operation; therefore, a one-step drilling operation was achieved. Full article

(This article belongs to the Special Issue High-Performance Machining Processes: From Mechanisms to Equipment)

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16 pages, 13170 KiB

Open AccessFeature PaperArticle

Prediction of Surface Location Error Considering the Varying Dynamics of Thin-Walled Parts during Five-Axis Flank Milling

by Yuyang Tang, Jun Zhang, Weixin Hu, Hongguang Liu and Wanhua Zhao

Processes 2023, 11(1), 242; https://doi.org/10.3390/pr11010242 - 11 Jan 2023

Cited by 1 | Viewed by 1853

Abstract

Surface location error (SLE) caused by forced vibration is a key factor to determine the quality of the finished part. When machining thin-walled structures with sculptured surfaces, the complicated milling process is significantly influenced by the vibration due to the flexibility of the part. The dynamics of the part are dominant and vary with the material removal during machining. This paper presents a prediction method of SLE considering the varying dynamics of thin-walled parts in five-axis flank milling. The in-process part is decomposed into unmachined and machined portions, which are both modelled based on the thin-plate theory. The dynamics models of the two portions are coupled using the substructure method. Coordinate transformation based on the screw theory and the general cutting dynamics model for five-axis flank milling is employed to transform the cutting force vectors and frequency response function (FRF) to the same coordinate system for the prediction of SLE. The proposed method is validated with five-axis flank milling tests and SLE measurements on a thin-walled twisted part. It is shown that the average error of the proposed method for SLE prediction is less than 5 μm, and the calculation is almost 8 times faster than the typical finite element method. Full article

(This article belongs to the Special Issue High-Performance Machining Processes: From Mechanisms to Equipment)

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15 pages, 3689 KiB

Open AccessArticle

Design and Development of a High-Speed Precision Internal Grinding Machine and the Associated Grinding Processes

by Zhou Chang, Qian Jia and Lai Hu

Processes 2023, 11(1), 64; https://doi.org/10.3390/pr11010064 - 27 Dec 2022

Cited by 1 | Viewed by 3274

Abstract

In order to meet the P2-grade bearing grinding requirements, we designed a high-speed internal grinding machine to be used for grinding bearing raceways and inner circles. The machine has a T-type layout and a four-axis numerical control linkage. It is supported by hydrostatic pressure and driven directly by a torque motor. In addition, it is equipped with a high-speed hydrostatic grinding wheel spindle. Our design includes a hydrostatic workpiece shaft and hydrostatic turntable, and the process has a good engineering application value. Finally, the designed precision grinding machine was used to grind a P2-grade bearing raceway. Full article

(This article belongs to the Special Issue High-Performance Machining Processes: From Mechanisms to Equipment)

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18 pages, 3629 KiB

Open AccessArticle

Influence of the Machining Process on the Thrust Force and Mechanical Characteristics for the Direct Drive System

by Xiaojun Yang, Junying Li, Jianlin Xuan and Wanhua Zhao

Processes 2023, 11(1), 17; https://doi.org/10.3390/pr11010017 - 22 Dec 2022

Cited by 3 | Viewed by 1425

Abstract

This paper investigates the effects of the machining process on the thrust force and mechanical characteristics for the direct drive feed system driven by the flat permanent magnet synchronous linear motor (PMSLM) in machine tools considering the electromechanical couplings. Firstly, the cutting force in the machining process is researched. Then, the analytical model of the direct drive feed system is established and analyzed. The electromechanical couplings between the mechanical system and servo system in the direct drive feed system are studied. Furthermore, the influences of the cutting force on different couplings are analyzed, and the thrust force characteristic is analytically represented. Finally, the validity of the theoretical analysis is verified by the experiments, and the effects of the machining process on the dynamic precision of the feed system are discussed. The results show that the electromechanical couplings in the direct drive system will aggravate the effects of the machining process on the thrust force and mechanical characteristics of the feed system. A large number of new paired thrust harmonics will be produced. The influence of the machining process on the mechanical system will be extended from the discrete frequency point caused by the cutting force to the approximate frequency band caused by the thrust force, affecting the dynamic precision of the feed system and the cutting stability of the machine tool. Full article

(This article belongs to the Special Issue High-Performance Machining Processes: From Mechanisms to Equipment)

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21 pages, 8502 KiB

Open AccessArticle

Digital Twin Modelling Method of Five-Axis Machine Tool for Predicting Continuous Trajectory Contour Error

by Dun Lyu, Jian Liu, Shiyou Luo, Shuo Liu, Qunlin Cheng and Hui Liu

Processes 2022, 10(12), 2725; https://doi.org/10.3390/pr10122725 - 16 Dec 2022

Cited by 1 | Viewed by 2228

Abstract

The CNC machine tool is the passive executor of machining code. It cannot predict the machining accuracy during machining. If the error is found to be out of tolerance after processing, it will not only scrap the parts, but also greatly affect the processing efficiency. This phenomenon is very prominent when machining sculptured surface parts with five-axis machine tools. Therefore, this paper proposes a Digital Twin (DT) modeling method of five-axis machine tools for predicting Continuous Trajectory Contour Error (CTCE) caused by tracking errors and geometric errors. The DT consists of three parts: the Setpoints Trajectory (ST) model, the Actual Trajectory (AT) model considering tracking errors and geometric errors and the CTCE model. For a specific machine tool, according to the basic geometric information of the machine tool (tool length, kinematic chain information, etc.) and 41 geometric errors, the DT can be established. Inputting the Setpoints Positions (SPs) and the Linear Encoder Detection Positions (LEDPs), the DT can be used to predict the Tool-Tip Position Trajectory (TTPT) contour error and the Tool Orientation Trajectory (TOT) contour error. In order to verify the proposed method experimentally, the KMC400S U five-axis machine tool is selected to establish its DT by which the contour error of the S-shaped trajectory are predicted offline. Then, the DMU50 five-axis machine tool is selected to establish its DT to predict the contour error of the circular trajectory in real time. Combined with the deep motion mechanism, this paper proposes a DT modeling method for the vertical application scene of parts machining accuracy prediction, which is of great significance to developing the DT application theory and ensuring the machining accuracy of parts. Full article

(This article belongs to the Special Issue High-Performance Machining Processes: From Mechanisms to Equipment)

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