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Novel Analysis of Tribological Characterization in Machining Processes

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

Deadline for manuscript submissions: closed (20 December 2022) | Viewed by 5596

Special Issue Editors


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Guest Editor
IDMEC, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal
Interests: machining; metal cutting; plasticity; tribology; ductile fracture; mechanical testing; machine tools

Special Issue Information

In machining technologies, friction between the cutting tool and the chip is a key parameter that influences the productivity and quality of the machined part. Despite this, obtaining realistic friction input data for simulation-based analysis and optimization methodologies remains an issue for several reasons. First, tribological conditions in metal cutting are significantly different from those observed in the well-established tribology of machine elements and metal forming processes, thus hindering the use of reference values and experimental techniques. Second, theoretical models are based exclusively on the mathematical theory of plasticity, which limits the capability to perform a realistic modeling of the friction mechanics. Understanding the microstructural and tribo-chemical phenomena occurring during the formation and sliding of the chip over the rake surface is of utmost importance for a physically realistic simulation of the machining processes.

This Special Issue will focus on the latest advances in machining tribology related to the development of new experimental techniques and comprehensive theoretical models to support the effective simulation of the chip formation mechanics. Review articles and novel research papers are invited, covering the following areas:

  • Original equipment and testing procedures focused on the interaction between chip, cutting tool, and surrounding environment for the independent characterization of friction.
  • Theoretical modeling and simulation of machining in a more comprehensive and contextualized approach in the study of friction and wear mechanics, as well as for the optimization of process conditions and quality of machined parts.
  • Novel contributions to the fundamental understanding of friction, lubrication, surface science, and advancement in the field of machining tribology are also objectives of this Special Issue.
  • Lastly, but no less important, it is appropriate to include case studies and solved problems elucidated with sufficient schematics, diagrams, and references to serve as a perfect textbook for targeted readers.

Prof. Dr. Pedro Rosa
Prof. Dr. Abílio M.P. De Jesus
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 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

  • machining
  • metal cutting
  • tribology
  • friction
  • lubrication
  • wear
  • dry sliding
  • surface roughness
  • tribo-oxidation
  • stick–slip

Published Papers (3 papers)

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Research

28 pages, 11070 KiB  
Article
Tribological Analysis of Several Coatings under Flood and Cryogenic Cooling Conditions
by Yutao Zhang, Jose C. Outeiro, Corinne Nouveau, Bertrand Marcon and Lamice A. Denguir
Appl. Sci. 2023, 13(21), 11743; https://doi.org/10.3390/app132111743 - 26 Oct 2023
Viewed by 962
Abstract
The contact between the tool and the workpiece/chip in metal cutting is complex, resulting in high local temperatures and stresses, which may cause severe tool wear and failure. Developments in cryogenic-assisted machining have shown an ecological alternative to the classical metal working fluids, [...] Read more.
The contact between the tool and the workpiece/chip in metal cutting is complex, resulting in high local temperatures and stresses, which may cause severe tool wear and failure. Developments in cryogenic-assisted machining have shown an ecological alternative to the classical metal working fluids, besides tool wear reduction during machining difficult-to-cut materials due to the good ability to dissipate the heat generated by this process. The objective of this work is to analyze the tribological conditions and performance of new coatings specially developed for cryogenic-assisted machining in terms of friction coefficient, volume of build-up material (adhesion) to the tool, and tool temperature. The results have shown that the sliding speed and cooling/lubrication strategy are two main factors that affect the friction coefficient and adhesion of Ti–6Al–4V alloy to the pins. These tribological tests should allow us to select the best coating(s) to be used in cutting tools for further tool wear analysis. Moreover, the obtained friction coefficients could be further implemented into metal cutting models to predict the machining outcomes, including the surface integrity of the machined parts and tool wear. Full article
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11 pages, 5473 KiB  
Article
Gloss and Modelling Studies of Stone Polishing Using Linear Polishing Machines with Rotating Heads
by Adriano Coelho, José Carlos Garcia Pereira, Pedro M. Amaral and Luís Guerra Rosa
Appl. Sci. 2022, 12(15), 7521; https://doi.org/10.3390/app12157521 - 26 Jul 2022
Viewed by 1548
Abstract
The ornamental stone industry has always played an important role in the world economy. Polishing the slabs to increase their gloss is important to enhance the beauty and richness of these natural materials. Many industrial polishing machines rely on a rotating head’s movement [...] Read more.
The ornamental stone industry has always played an important role in the world economy. Polishing the slabs to increase their gloss is important to enhance the beauty and richness of these natural materials. Many industrial polishing machines rely on a rotating head’s movement along zigzag trajectories (controlled by belt, transverse and rotational speeds), to erode the surface as stochastically as possible (to avoid scratches and other visual defects caused by paths that are too symmetrical). Optimizing (and automatizing) these three speeds together therefore represents a significant gain for the industry, in time, energy, and quality of product. In this work we show that this optimization can be accomplished by fulfilling these conditions: (1) the displacement of the polishing head after a single zigzag movement should be smaller than its diameter; and (2) the displacement of the polishing head after a single rotation should be smaller than its radius. To assess the validity of these two conditions, we studied the polishing activity using experiments based on gloss measurements of the polished stone and computer simulations based on the geometric contacts between the tool and the stone. We concluded that: (i) a clear correlation can be established between experimental and simulation data; (ii) the two displacement parameters represent an effective way to control the quality and efficiency of the polishing process; and (iii) there is a limit to the gloss acquired through polishing processes, thus polishing above a given threshold decreases the efficiency without increasing the quality. The correspondence between experimental and modelling results opens the door to further optimizations of these polishing processes in the future. Full article
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14 pages, 5662 KiB  
Article
Effect of Surface Micro-Hardness Change in Multistep Machining on Friction and Wear Characteristics of Titanium Alloy
by Guanming Hou and Anhai Li
Appl. Sci. 2021, 11(16), 7471; https://doi.org/10.3390/app11167471 - 14 Aug 2021
Cited by 16 | Viewed by 2028
Abstract
The machined surface quality, especially the micro-hardness of machined surface layers, is strongly correlated to the friction and wear characteristics of titanium alloy engineering parts. Therefore, to explore relationship of the local surface micro-hardness change in multistep machining and the surface wear resistance [...] Read more.
The machined surface quality, especially the micro-hardness of machined surface layers, is strongly correlated to the friction and wear characteristics of titanium alloy engineering parts. Therefore, to explore relationship of the local surface micro-hardness change in multistep machining and the surface wear resistance of the machined parts is urgently necessary. The machined surfaces were acquired through two-step (roughing and finishing) and three step (roughing, semi-finishing, and finishing) cylindrical turning experiments. The dry friction and wear tests were carried out by UMT-2 friction and wear tester on the multistep final machined surface along the feed direction. The surface wear microtopography and subsurface microstructure were observed and analyzed by scanning electron microscope. The micro-hardness variation in the local area of the finishing surface will cause the extension of unstable friction time stage while withstanding the cyclic and alternating contact stresses, and the soft–hard alternating area should be the sources of friction and wear defects, for instance cracks, peeling pits, fracture striations and even the wear fracture zone to crack propagation and peeling off. This will be of great significance to accurately control the machined surface quality and adaptively improve the surface wear resistance of titanium alloy components. Full article
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