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Applied Sciences
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Advanced Manufacturing and Precision Machining
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Advanced Manufacturing and Precision Machining

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: 20 October 2024 | Viewed by 9626

Special Issue Editor

Dr. Wei Li

E-Mail Website
Guest Editor
College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, China
Interests: precision machining; grinding; cutting; machine tool; grinding tool; lubrication and cooling; intelligent processing; nanofluids; plasma processing

Special Issue Information

Dear Colleagues,

The cornerstone industry for social and economic advancement is the manufacturing of machinery. Advanced manufacturing, on the other hand, is based on the traditional manufacturing industry, but incorporates electronic information, computers, machinery, materials, and other advanced technology that has high-quality, high-efficiency, low-consumption, clean, and flexible-production properties.

The term "precision machining" refers to machining with an accuracy from 10 to 0.1 microns and a surface roughness of 0.1 microns or less. Precision machining is a significant component of the advanced manufacturing sector. The processing of essential components such as precision screws, precision gear, precision worm gear, precision guides, and precision bearings frequently involves precision machining, which plays a significant role in the manufacturing sector. However, there are still some technical issues in the field of advanced manufacturing that need to be resolved, such as how to balance the link between machining accuracy and machining efficiency. The manufacturing sector's development is undoubtedly going in the direction of advanced manufacturing and precision machining, which will significantly aid in both the economic growth and the establishment of new industries.

In order to improve technical communication, advance related technologies, and present fresh concepts and experimental findings in the field of advanced manufacturing and precision machining from theory and design to real-world applications, this Special Issue will be devoted to the current status and new perspectives on the development of advanced manufacturing and precision machining.

Dr. Wei Li
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. Applied Sciences 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 2400 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

  • precision machining
  • micro- and nanoprocessing
  • mechanical systems
  • surface quality
  • ultraprecision manufacturing

Published Papers (9 papers)

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Research

13 pages, 5040 KiB  
Article
Stability Analysis of the Rapid Heating Multilayer Structure Mold by the Contact Error and Thickness of Layers
by Hyeonmin Lee, Youngbae Ko and Woochun Choi
Appl. Sci. 2024, 14(7), 2813; https://doi.org/10.3390/app14072813 - 27 Mar 2024
Viewed by 445
Abstract
Rapid heating of the mold surface is necessary for the high-gloss, high-productivity injection molding process. A rapid heating mold system that uses a carbon nanotube (CNT) as a heating element was investigated because of its structure. For CNT web film to be utilized [...] Read more.
Rapid heating of the mold surface is necessary for the high-gloss, high-productivity injection molding process. A rapid heating mold system that uses a carbon nanotube (CNT) as a heating element was investigated because of its structure. For CNT web film to be utilized in the injection molding process, heating must be applied inside the mold. That can cause poor contact at the contact area between the mold and the CNT heating element, leading to local temperature deviation and resistance changes that reduce the heating stability of the CNT surface element. Additionally, the multilayer structure of the CNT web film can cause heat-transfer performance variations due to the different layer thicknesses. To address these issues, an adjustable flush was constructed at the contact area between the electrode inside the mold and the insulator to analyze the heating behavior of the CNT heating element as a function of dimensional deviation. The thermal durability of the CNT web film was also evaluated by analyzing the Raman spectra and measuring resistance changes caused by local overheating. The film can withstand high temperatures, with a flush limit value of 0.3 mm. An optimization analysis was conducted to determine the ideal thicknesses of the multilayer CNT web film, insulator, and electrical insulator. Optimal layer thicknesses were found to be 10 μm, 5 mm, and 0.5 mm, respectively. The main variables of the rapid heating mold required for application to the injection process were identified and reflected in the mold design to suggest directions for commercialization. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Precision Machining)
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22 pages, 7765 KiB  
Article
Optimization of Pin Type Single Screw Mixer for Fabrication of Functionally Graded Materials
by Shijie Wang, Jing Zhou and Guolin Duan
Appl. Sci. 2024, 14(3), 1308; https://doi.org/10.3390/app14031308 - 05 Feb 2024
Viewed by 462
Abstract
The direct ink writing (DIW) process, used for creating components with functionally graded materials, holds significant promise for advancement in various advanced fields. However, challenges persist in achieving complex gradient variations in small-sized parts. In this study, we have developed a customized pin [...] Read more.
The direct ink writing (DIW) process, used for creating components with functionally graded materials, holds significant promise for advancement in various advanced fields. However, challenges persist in achieving complex gradient variations in small-sized parts. In this study, we have developed a customized pin shape for an active screw mixer using a combination of quadratic B-Spline, the response surface method, and global optimization. This tailored pin design was implemented in a two-material extrusion-based printing system. The primary objective is to facilitate the transformation of material components with shorter transition distances, overcoming size constraints and enhancing both printing flexibility and resolution. Moreover, we characterized the transition delay time for material component changes and the mixing uniformity of the extruded material by constructing a finite element simulation model based on computational fluid dynamics. Additionally, we employed a particle tracking method to obtain the Lyapunov exponent and Poincaré map of the mixing process. We employed these metrics to represent and compare the degree of chaotic mixing and dispersive mixing ability with two other structurally similar mixers. It was found that the optimized pin-type mixer can reduce the transition delay distance by approximately 30% compared to similar structures. Finally, comparative experiments were carried out to verify the printing performance of the optimized pin-type active mixer and the accuracy of the finite element model. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Precision Machining)
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16 pages, 4459 KiB  
Article
Research on Visualization Technology of Production Process for Mechanical Manufacturing Workshop
by Li Li, Zhaoyun Wu and Liping Lu
Appl. Sci. 2023, 13(17), 9754; https://doi.org/10.3390/app13179754 - 29 Aug 2023
Viewed by 1925
Abstract
The visualization of workshop information can affect production management and efficiency. Information can be presented both graphically and non-graphically (for example, in the form of data lists or tables). Graphical representations are intuitive and clear, but currently, most of them are based on [...] Read more.
The visualization of workshop information can affect production management and efficiency. Information can be presented both graphically and non-graphically (for example, in the form of data lists or tables). Graphical representations are intuitive and clear, but currently, most of them are based on statistical data, which makes it difficult to convey logical linkages between information and cannot help managers make decisions effectively. With the aim of designing the workshop production system with visual processes in small-sized enterprises, the key visualization technologies of the process flow chart, including the visual design of process flow chart, process card management, process flow chart release, process control, and production schedule monitoring, were all addressed in detail. On this basis, the mechanical manufacturing workshop production management system was created using C#.NET as the programming language. The main contribution of the research is that the system designed used the process flow chart as the main line through all functional modules and integrated all process data on the process nodes of the process flow chart to realize the graphical monitoring of workshop production schedule. The visualization technology of the process flow chart makes the system simple to use and easy to understand, which significantly improves information management and work efficiency in the workshop. Additionally, it provides the technical foundation for flow-driven production information transfer in the workshop and can serve as a universal standard for the process module in workshop production management systems. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Precision Machining)
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17 pages, 2408 KiB  
Article
Flexible Job Shop Scheduling Optimization for Green Manufacturing Based on Improved Multi-Objective Wolf Pack Algorithm
by Jian Li, Huankun Li, Pengbo He, Liping Xu, Kui He and Shanhui Liu
Appl. Sci. 2023, 13(14), 8535; https://doi.org/10.3390/app13148535 - 24 Jul 2023
Viewed by 1038
Abstract
Green manufacturing has become a new production mode for the development and operation of modern and future manufacturing industries. The flexible job shop scheduling problem (FJSP), as one of the key core problems in the field of green manufacturing process planning, has become [...] Read more.
Green manufacturing has become a new production mode for the development and operation of modern and future manufacturing industries. The flexible job shop scheduling problem (FJSP), as one of the key core problems in the field of green manufacturing process planning, has become a hot topic and a difficult issue in manufacturing production research. In this paper, an improved multi-objective wolf pack algorithm (MOWPA) is proposed for solving a multi-objective flexible job shop scheduling problem with transportation constraints. Firstly, a multi-objective flexible job shop scheduling model with transportation constraints is established, which takes the maximum completion time and total energy consumption as the optimization objectives. Secondly, an improved wolf pack algorithm is proposed, which designs individual codes from two levels of process and machine. The precedence operation crossover (POX) operation is used to improve the intelligent behavior of wolves, and the optimal Pareto solution set is obtained by introducing non-dominated congestion ranking. Thirdly, the Pareto solution set is selected using the gray relational decision analysis method and analytic hierarchy process to obtain the optimal scheduling scheme. Finally, the proposed algorithm is compared with other algorithms through a variety of standard examples. The analysis results show that the improved multi-objective wolf pack algorithm is superior to other algorithms in terms of solving speed and convergence performance of the Pareto solution, which shows that the proposed algorithm has advantages when solving FJSPs. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Precision Machining)
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14 pages, 9590 KiB  
Article
Investigation of Spatial Symmetry Error Measurement, Evaluation and Compensation Model for Herringbone Gears
by Zhipeng Liang and Huawei Zhou
Appl. Sci. 2023, 13(14), 8340; https://doi.org/10.3390/app13148340 - 19 Jul 2023
Viewed by 686
Abstract
In the machining process for herringbone gears manufactured by numerical control gear-shaping machines, out-of-tolerance problems of symmetry error generally exist. This paper proposed a high-precision control of spatial symmetry error in the one-time forming machining for herringbone gear. To improve the machining symmetry [...] Read more.
In the machining process for herringbone gears manufactured by numerical control gear-shaping machines, out-of-tolerance problems of symmetry error generally exist. This paper proposed a high-precision control of spatial symmetry error in the one-time forming machining for herringbone gear. To improve the machining symmetry accuracy and quality of herringbone gear, a mathematical model of measurement, evaluation and compensation for spatial symmetry error was established based on the least square method. Meanwhile, a new shaping machining method based on spatial symmetry error detection and compensation was proposed. The test results indicated that the proposed method can maintain symmetry within 0.02 mm. This study provided a novel spatial symmetry error detection and compensation machining method for herringbone gear that has advantages compared to traditional methods in terms of machining accuracy, efficiency, and continuous machining type. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Precision Machining)
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19 pages, 11347 KiB  
Article
A Polishing Processes Optimization Method for Ring-Pendulum Double-Sided Polisher
by Shuning Liang, Bo Xiao, Chunyang Wang, Lin Wang and Zishuo Wang
Appl. Sci. 2023, 13(13), 7893; https://doi.org/10.3390/app13137893 - 05 Jul 2023
Viewed by 649
Abstract
This paper presents an optimization method that aims to mitigate disturbances in the radial-feed system of the ring-pendulum double-sided polisher (RDP) during processing. We built a radial-feed system model of an RDP and developed a single-tube robust model predictive control system to enhance [...] Read more.
This paper presents an optimization method that aims to mitigate disturbances in the radial-feed system of the ring-pendulum double-sided polisher (RDP) during processing. We built a radial-feed system model of an RDP and developed a single-tube robust model predictive control system to enhance the disturbance rejection capability of the radial-feed system. To constrain the system states inside the terminal constraint set and further enhance the system’s robustness, we added the ε-approximation to approach the single-tube terminal constraint set. Finally, the effectiveness of the proposed method for the RDP radial-feed system was verified through simulations and experiments. These findings demonstrate the potential of the proposed method for improving the performance of the RDP radial-feed system in practical applications. The polish processing results demonstrated a substantial improvement in the accuracy of the surface shape measurements obtained by applying the STRMPC method. Compared to the MPC method, the PV value decreased from 1.49 λ PV to 0.99 λ PV, indicating an improvement in the convergence rate of approximately 9.78%. Additionally, the RMS value decreased from 0.257 λ RMS to 0.163 λ RMS, demonstrating a remarkable 35.6% enhancement in the convergence rate. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Precision Machining)
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16 pages, 8140 KiB  
Article
Research on Cutting Temperature of GH4169 Turning with Micro-Textured Tools
by Xinmin Feng, Xiwen Fan, Jingshu Hu and Jiaxuan Wei
Appl. Sci. 2023, 13(11), 6832; https://doi.org/10.3390/app13116832 - 05 Jun 2023
Cited by 1 | Viewed by 1026
Abstract
The GH4169 superalloy has the characteristics of high strength, strong thermal stability, large specific heat capacity, small thermal conductivity, etc., but it is also a typical hard-to-cut material. When cutting this material with ordinary cutting tools, the cutting force is large, and the [...] Read more.
The GH4169 superalloy has the characteristics of high strength, strong thermal stability, large specific heat capacity, small thermal conductivity, etc., but it is also a typical hard-to-cut material. When cutting this material with ordinary cutting tools, the cutting force is large, and the cutting temperature is high, which leads to severe tool wear and short service life. In order to improve the performance of tools when cutting GH4169, reduce the cutting temperature, and extend the service life of the tool, micro-textured tools were used to cut GH4169 in spray cooling. The effects of micro-texture morphology and dimensional parameters on cutting temperature were analyzed. Firstly, tools with micro-textures of five different morphologies were designed near the nose on the rake face of the cemented carbide tools. The three-dimensional cutting models of the micro-textured tools with different morphologies were established by using ABAQUS, and a simulation analysis was carried out. Compared with the non-textured tools, the micro-texture morphology with the lowest cutting temperature was selected according to the simulation results of the cutting temperature. Secondly, based on the optimized morphology, tools with micro-textures of different size parameters were designed. When cutting GH4169, the cutting temperature of the tools was simulated and analyzed, and the size parameters of the micro-textured tools with the lowest cutting temperature were selected as well. Finally, the designed micro-textured tools were processed and applied in cutting experiments. The simulation model was verified in the experiments, and the influence of size parameters of micro-textures on the cutting temperature was analyzed. This paper provides a theoretical reference and basis for cutting GH4169 and the design and application of micro-textured tools. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Precision Machining)
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16 pages, 6524 KiB  
Article
Study on Preparation and Processing Properties of Mechano-Chemical Micro-Grinding Tools
by Xin Song, Feifan Ke, Keyi Zhu, Yinghui Ren, Jiaheng Zhou and Wei Li
Appl. Sci. 2023, 13(11), 6599; https://doi.org/10.3390/app13116599 - 29 May 2023
Cited by 1 | Viewed by 960
Abstract
The application of hard and brittle materials such as single-crystal silicon in small parts has expanded sharply, and the requirements for their dimensional accuracy and processing surface quality have been continuously improved. This paper proposes using mechano-chemical micro-grinding tools to process single-crystal silicon, [...] Read more.
The application of hard and brittle materials such as single-crystal silicon in small parts has expanded sharply, and the requirements for their dimensional accuracy and processing surface quality have been continuously improved. This paper proposes using mechano-chemical micro-grinding tools to process single-crystal silicon, which can realize the high-quality and efficient processing of such tiny parts through mechano-chemical composite action. The microstructure composition of the mechano-chemical micro-grinding tools was designed, the theoretical analysis model of grinding force was established and verified by experiments, and the temperature field distribution during mechano-chemical micro-grinding of single-crystal silicon was simulated and studied, which provided a theoretical basis for mechano-chemical action. Special micro-grinding tools were developed, and mechano-chemical micro-grinding processing tests were carried out. The results show that the coupling synergy of grinding force and grinding temperature improves the chemical activity of the micro-grinding tools, thereby promoting the solid–solid phase chemical reaction of abrasives and additives at the sharp points of the surface of the micro-grinding tools. And when the content of cerium oxide abrasive is 25%, it is more conducive to the solid–solid phase chemical reaction, and calcium oxide can be used as an additive to promote the active agent of solid–solid phase chemical reaction, improve the degree of chemical reaction, and thus improve the removal rate of materials. Soft reactants that are easy to remove are generated on the surface of monocrystalline silicon and are removed by the mechanical friction between the abrasive grain and the surface of the silicon wafer, and finally achieve low-damage processing with a surface roughness of Ra1.332 nm, which is much better than the surface roughness of Ra96.363 nm after diamond abrasive processing. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Precision Machining)
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15 pages, 5275 KiB  
Article
Design of a Quick-Pressing and Self-Locking Temporary Fastener for Easy Automatic Installation and Removal
by Wei Tang, Jie He, Yunya Xiao, Weiwei Qu, Jiying Ye, Hui Long and Chaolin Liang
Appl. Sci. 2023, 13(5), 3004; https://doi.org/10.3390/app13053004 - 26 Feb 2023
Viewed by 1534
Abstract
In the traditional pre-joining technology of aircraft panels, bolts are generally employed for pre-joining. Due to the length and width of panels, bilateral manual operations are required to operate bolts. In this case, there are problems such as low work efficiency, unstable quality, [...] Read more.
In the traditional pre-joining technology of aircraft panels, bolts are generally employed for pre-joining. Due to the length and width of panels, bilateral manual operations are required to operate bolts. In this case, there are problems such as low work efficiency, unstable quality, cumbersome operation, and inconvenient installation-removal. This paper takes a temporary fastener with one-side installation-removal as a research object and conducts in-depth research on three levels of quick-pressing: unloading, stable self-locking, and easy automatic installation. Firstly, by coordinating the ratchet and the spring, the restoring force of the spring is used to make the cylindrical top-rod rotary and realize the telescopic function to achieve quick loading and unloading of fasteners; subsequently, through the cooperation between the buckle and the spring, loading and unloading self-locking is attained; afterwards, through the threaded joining and the same cylinder design between the external profile components, the convenience of fasteners for automatic transportation is realized. When assembling two thin-walled parts of the aircraft, only continuous one-side pressing of fasteners is needed to carry out the tightening and unloading work, namely, one-pressing installation and one-pressing removal, which could solve the problems caused by the bilateral operation of traditional bolts and part tolerances. After the application of the fasteners into the pre-joining process of aircraft panels, the experiment results have shown that this temporary fastener provided a good clamping effect, could be quickly and efficiently installed and removed by continuous one-pressing, and avoided the problems of complexity and high cost for pre-joining processes. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Precision Machining)
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