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Coatings
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New Cutting Techniques for Improved Machining
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New Cutting Techniques for Improved Machining

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Surface Characterization, Deposition and Modification".

Deadline for manuscript submissions: closed (20 September 2022) | Viewed by 6526

Special Issue Editor

Dr. Martin Novák

E-Mail Website
Guest Editor
Faculty of Mechanical Engineering, Jan Evangelista Purkyně University in Ústí nad Labem, Pasteurova 7, 40096 Ústí nad Labem, Czech Republic
Interests: machining; surface quality; grinding; material testing

Special Issue Information

Dear Colleagues,

Current trends in machining emphasize the implementation of new machining methods based on the use of progressive cutting materials, reducing machine times, shortening production lead times, and respecting environmental as well as economic aspects. Machining technology must also actively respond to the growing use of new and innovative types of ferrous or non-ferrous materials, especially the requirements for higher mechanical properties, wear resistance, durability, and reliability. The new trends, therefore, include necessary information from the field of science and research on progressive cutting materials, design parameters of machine tools, construction and design of cutting tools, research and impacts of the cutting environment, the influence of chemical composition and heat treatment on material machinability, and long-term durability tests of machine parts. In today's level of materials engineering and production technologies, materials prepared by additive technologies that are specific for their physical, chemical, and mechanical properties, progressive composite materials and a large group of biocompatible materials, production and processing is difficult. The level of machining production technology must carry out continuous research activities that find the optimal cutting conditions for machining the above types of materials with the appropriate quality of the machined surface. The quality of the machined surface is one of the basic indicators of how to analyze and evaluate the machined surface in terms of its quality parameters, the compliance of the required properties with reality, and maintaining the required service life of machine parts based on defined parameters.

Topics:

  • Additive technologies and their influence on machinability.
  • Analysis of surface quality.
  • Design of cutting tools.
  • Finishing.
  • Influence of the chemical and mechanical properties on materials machinability.
  • Machinability of biomaterial and difficult-to-cut materials.
  • Machinability of progressive materials.
  • New trends in machining and finishing.
  • New types of cutting materials.
  • Study of the machining environment.
  • Study of surface integrity.
  • The economic and environmental aspects of machining.

Dr. Martin Novák
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. Coatings 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

  • analysis
  • cutting tools
  • finishing
  • machining
  • surface quality

Published Papers (4 papers)

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Research

11 pages, 7764 KiB  
Article
Optimization of Crystalline Diamond Coating Structure Architecture for Improving Adhesion and Cutting Performance in Milling with Cemented Carbide Inserts
by Georgios Skordaris, Konstantinos-Dionysios Bouzakis, Antonios Bouzakis, Dimitrios Tsakalidis, Apostolos Boumpakis, Spyridon Kompogiannis, Emmanouil Bouzakis, Oliver Lemmer, Werner Kölker and Michael Woda
Coatings 2023, 13(7), 1170; https://doi.org/10.3390/coatings13071170 - 28 Jun 2023
Cited by 1 | Viewed by 1644
Abstract
The adhesion, structure architecture, and residual stresses of crystalline diamond coatings (CDCs) on cemented carbide inserts are the factors that significantly affect tool life. The influence of these factors on cutting performance cannot be investigated separately since interactions among them exist. The paper [...] Read more.
The adhesion, structure architecture, and residual stresses of crystalline diamond coatings (CDCs) on cemented carbide inserts are the factors that significantly affect tool life. The influence of these factors on cutting performance cannot be investigated separately since interactions among them exist. The paper elucidates such dependencies to optimize the CDC architecture and improve cutting performance. In this context, diamond coatings possessing different architectures were deposited on cemented carbide tools. The fatigue endurance and the milling performance of the coated tools were investigated using impact and milling tests, respectively. The residual stresses in the film structures were determined through impact tests and appropriate (Finite Element Analysis) FEA evaluation of the corresponding results. According to the obtained results, the application of a bottom micro-structured CDC prior to the deposition of an upper nanolayered one with inferior thickness improves the coated tools’ cutting performance. An optimum coating architecture is associated with a thickness ratio between the micro-structured bonding to the upper nanolayered CDCs of 2/1. Hereupon, the augmentation of coated tool life via the application of an optimum diamond coating architecture compensates for the high tool cost and improves milling productivity. The latter is further enhanced as the number of tool replacements decreases. Full article
(This article belongs to the Special Issue New Cutting Techniques for Improved Machining)
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23 pages, 33504 KiB  
Article
Wear Study of Coated Mills during Circumferential Milling of Carbon Fiber-Reinforced Composites and Their Influence on the Sustainable Quality of the Machined Surface
by Tomáš Knápek, Štěpánka Dvořáčková and Artur Knap
Coatings 2022, 12(10), 1379; https://doi.org/10.3390/coatings12101379 - 21 Sep 2022
Cited by 2 | Viewed by 1187
Abstract
Composite materials made of fiber-reinforced plastic laminates are highly susceptible to surface damage caused by wear during contour milling, especially with inappropriate tool and cutting material properties. Improper choice of tools and cutting conditions lead to delamination between applied layers, thermal damage of [...] Read more.
Composite materials made of fiber-reinforced plastic laminates are highly susceptible to surface damage caused by wear during contour milling, especially with inappropriate tool and cutting material properties. Improper choice of tools and cutting conditions lead to delamination between applied layers, thermal damage of materials in the polymer matrix, and reduction of the edge quality of cutting tools. The study was devoted to circumferential milling of twill-bonded CFRP (carbon-fiber-reinforced polymer) sheets with a focus on cutting forces and tool flank face wear, including their effect on the machined surface structure, roughness, and topography of the laminate. The main objective of the study is to investigate the feasibility of applying conventional coated tools, which are not primarily designed for milling CFRP, in comparison to a dedicated DLC (diamond-like carbon) coated tool, due to economic and distribution availability and the possibility of providing suitable cutting conditions during milling. The study provides results confirming the possibility of using conventional tools for machining CFRP and provides relevant experimental results that can be implemented for optimal tool selection, tool life criteria, cutting conditions, and machining strategies including low energy consumption. The best values of the investigated parameters were obtained when using the ECSSF (instrument designation) tool with DLC coating. Full article
(This article belongs to the Special Issue New Cutting Techniques for Improved Machining)
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15 pages, 6085 KiB  
Article
Study of the Machining Process of GFRP Materials by Milling Technology with Coated Tools
by Artur Knap, Štěpánka Dvořáčková and Tomáš Knápek
Coatings 2022, 12(9), 1354; https://doi.org/10.3390/coatings12091354 - 16 Sep 2022
Cited by 4 | Viewed by 1414
Abstract
Glass fibers are often used as reinforcing fibers in reinforced polymers. Composites reinforced with glass fibers (GFRP) stand out with excellent mechanical and physical properties applicable to industrial practice. Machining these composites requires the correct choice of tools and cutting conditions so that [...] Read more.
Glass fibers are often used as reinforcing fibers in reinforced polymers. Composites reinforced with glass fibers (GFRP) stand out with excellent mechanical and physical properties applicable to industrial practice. Machining these composites requires the correct choice of tools and cutting conditions so that the machined surface shows good properties, there is no fiber delamination, thermal stress on the workpiece and the tool, or excessive tool wear. The study was devoted to circumferential milling of fabric-bonded GFRP plates, in which attention was paid to the influence of the abrasive effect of glass fibers on wear and tool life. Attention was also paid to surface roughness after machining, material delamination, and forces during machining were measured. Three end mills of the same diameter with different coatings, number of teeth, and geometry were selected for the study. This choice of tools was intended to achieve various accompanying and subsequent phenomena that were investigated. Milling was performed on a CNC milling center under preselected cutting conditions. The paper summarizes information on fiber delamination and machined laminate damage after milling, tool wear, and surface roughness parameters as a function of tool wear. This paper provides an opportunity for researchers to increase their knowledge of specific aspects of milling GFRP composites, whether with a tool specifically designed for this or not. Full article
(This article belongs to the Special Issue New Cutting Techniques for Improved Machining)
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15 pages, 11477 KiB  
Article
Analyses of Tool Wear and Chip Type for Different Coated Carbide Inserts in Turning Hardened 1.6582 Steel
by Karel Šramhauser, Nataša Náprstková, Jan Sviantek, Dana Stančeková, Nguyen Van Tuong and Jan Novotný
Coatings 2022, 12(7), 974; https://doi.org/10.3390/coatings12070974 - 08 Jul 2022
Cited by 2 | Viewed by 1850
Abstract
This article deals with the comparative wear of CNMG-coated sintered carbide indexable cutting inserts by several manufacturers when turning 1.6582 steel hardened to 40–44 HRC. The main goal will be to demonstrate the different course of wear by testing seemingly identical inserts for [...] Read more.
This article deals with the comparative wear of CNMG-coated sintered carbide indexable cutting inserts by several manufacturers when turning 1.6582 steel hardened to 40–44 HRC. The main goal will be to demonstrate the different course of wear by testing seemingly identical inserts for engineering companies, showing the connection between the course of wear and the production of waste in the form of chips. The monitored type of wear was the flank wear VBmax of a cutting tool depending on the length of the machining time. Additionally, the effect of cutting tool wear on chip production, i.e., their quantity, shape and size, was monitored. For the purpose of mutual comparison, uniform cutting conditions were chosen on the basis of previous experiments, ensuring the stability of the given cutting process. For flank wear analysis, optical and electron microscopes were used. Meanwhile, a portable roughness tester was used to analyze the roughness of the machined surface. It was found that the quality of the interconnected coating layers has a perceptible influence on wear rate of the evaluated cutting inserts. The relation between the degree and characteristics of wear on the one hand, and the properties of the produced chips that identify the effect of the difference in the deposition layers using EDX/SEM analysis on the other, foreshadows the importance of choose between products with similarly declared properties was found. The current assessment of cutting tool wear and the evaluation of the chip produced has significant economic potential for manufacturing companies seeking to minimize costs. Full article
(This article belongs to the Special Issue New Cutting Techniques for Improved Machining)
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