Surface Integrity in Metals Machining

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: closed (31 May 2023) | Viewed by 7042

Special Issue Editors


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Guest Editor
School of Mechanical Engineering, Tongji University, Shanghai 201804, China
Interests: advanced manufacturing; surface integrity; laser machining; micro-nano cutting and mechanics; thin-walled workpiece machining; vibration suppression

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Guest Editor
School of Mechanical Engineering, Shandong University, Jinan 250061, China
Interests: metal cutting and cutting tools; high-speed machining; machined surface integrity; material dynamic properties
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Guest Editor
Division of Production and Materials Engineering, Department of Mechanical Engineering Sciences, LTH, Lund University, SE-221 00 Lund, Sweden
Interests: cutting tools; high performance machining; innovative design; wear of materials; monitoring; sustainable manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear colleagues,

With the increasing requirement of component quality in industry applications, surface integrity has become an essential aspect for the machined workpiece working in harsh environments, especially for those applied in safety critical areas (e.g., aerospace, nuclear, medical). Thus, the investigation of surface characteristics after machining has become of high importance and attracted growing attention from both academic and industrial researchers. However, due to the complex machining process, there is still a lack of comprehensive understanding of machined surface integrity and its formation mechanism, which has significantly limited the investigation of component service and functional performances. Considering the diversity of materials and machining methods, e.g., conventional and nonconventional machining, this Special Issue will focus on surface integrity in metal machining, aiming to make a fundamental contribution to exploring metal surface generation, as well as component functional performances.

In this Special Issue, we are particularly interested in (but not limited to) studies on topics such as:

  • Special mechanism in metal machining and deformation;
  • Surface and subsurface generation;
  • Material removal principle of non-conventional machining processes;
  • Surface and subsurface properties after machining (e.g., microstructure alternations, chemical variation, mechanical properties changing);
  • Surface integrity improvement and modification strategy;
  • Novel and advanced metal machining methods;
  • New surface integrity predication methods;
  • Influence of surface integrity on component functional performance;
  • Advanced surface integrity characterization methods;
  • Relationships of structure–process–surface integrity–performance.

Dr. Dongdong Xu
Prof. Dr. Bing Wang
Prof. Dr. Jinming Zhou
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. Journal of Manufacturing and Materials Processing 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 1800 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

  • surface integrity
  • metal cutting
  • machining
  • non-conventional machining
  • surface generation
  • materials deformation
  • functional performance

Published Papers (3 papers)

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Research

25 pages, 5389 KiB  
Article
In-Process Chatter Detection in Milling: Comparison of the Robustness of Selected Entropy Methods
by Barbora Hauptfleischová, Lukáš Novotný, Jiří Falta, Martin Machálka and Matěj Sulitka
J. Manuf. Mater. Process. 2022, 6(5), 125; https://doi.org/10.3390/jmmp6050125 - 21 Oct 2022
Cited by 2 | Viewed by 1747
Abstract
This article deals with the issue of online chatter detection during milling. The aim is to achieve a verification of the reliability and robustness of selected methods for the detection of chatter that can be evaluated on the machine tool in real time [...] Read more.
This article deals with the issue of online chatter detection during milling. The aim is to achieve a verification of the reliability and robustness of selected methods for the detection of chatter that can be evaluated on the machine tool in real time by using the accelerometer signal. In the introductory part of the paper, an overview of the current state of the art in the field of chatter detection is summarized. Entropic methods have been selected that evaluate the presence of chatter from the qualitative behavior of the signal rather than from the magnitude of its amplitude, because the latter can be affected by the transmission of vibrations to the accelerometer position. Another criterion for selection was the potential for practical implementation in a real-time evaluation of the accelerometer signal, which is nowadays quite commonly installed on machine tools. The robustness of the methods was tested with respect to tool compliance, which affects both chatter occurrence and vibration transfer to the accelerometer location. Therefore, the study was carried out on a slender milling tool with two different overhangs and on a rigid roughing tool. The reference stability assessment for each measurement was based on samples of the machined surface. The signals obtained from the accelerometer were then post-processed and used to calculate the chatter indicators. In this way, it was possible to compare different methods in terms of their ability to achieve reliable in-process detection of chatter and in terms of the computational complexity of the indicator. Full article
(This article belongs to the Special Issue Surface Integrity in Metals Machining)
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16 pages, 3357 KiB  
Article
2D FEM Investigation of Residual Stress in Diamond Burnishing
by Csaba Felhő and Gyula Varga
J. Manuf. Mater. Process. 2022, 6(5), 123; https://doi.org/10.3390/jmmp6050123 - 19 Oct 2022
Cited by 4 | Viewed by 1636
Abstract
Sliding friction diamond burnishing is a finishing machining operation whose purpose is to improve the surface integrity of previously machined surfaces and increase their surface hardness. When analyzing a complex process involving plastic deformation, friction, and the interaction between solids, finite element models [...] Read more.
Sliding friction diamond burnishing is a finishing machining operation whose purpose is to improve the surface integrity of previously machined surfaces and increase their surface hardness. When analyzing a complex process involving plastic deformation, friction, and the interaction between solids, finite element models (FEMs) involve a significant amount of simplification. The aim of this study is to investigate a 2D FEM of the residual stress occurring during diamond burnishing. Before burnishing, the samples were processed by fine turning. Based on the simulations and laboratory experiments performed, it can be concluded that the diamond burnishing process can be modeled with relatively good approximation using two-dimensional modeling. It was also concluded that it is important to consider the initial surface topography in two-dimensional tests. The results indicate that the diamond burnishing process improved the residual stress properties of EN 1.4301 austenitic stainless steel by creating relatively high compressive stress, whose magnitude was between 629 and 1138 MPa depending on the applied force. However, the stress distribution is not uniform; it is mostly concentrated under the roughness peaks. Full article
(This article belongs to the Special Issue Surface Integrity in Metals Machining)
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17 pages, 9602 KiB  
Article
Adapting the Surface Integrity of High-Speed Steel Tools for Sheet-Bulk Metal Forming
by Wolfgang Tillmann, Dominic Stangier, Alexander Meijer, Eugen Krebs, Alexander Ott, Timo Platt, Nelson Filipe Lopes Dias, Leif Hagen and Dirk Biermann
J. Manuf. Mater. Process. 2022, 6(2), 37; https://doi.org/10.3390/jmmp6020037 - 18 Mar 2022
Cited by 8 | Viewed by 2665
Abstract
New manufacturing technologies, such as Sheet-Bulk Metal Forming, are facing the challenges of highly stressed tool surfaces which are limiting their service life. For this reason, the load-adapted design of surfaces and the subsurface region as well as the application of wear-resistant coatings [...] Read more.
New manufacturing technologies, such as Sheet-Bulk Metal Forming, are facing the challenges of highly stressed tool surfaces which are limiting their service life. For this reason, the load-adapted design of surfaces and the subsurface region as well as the application of wear-resistant coatings for forming dies and molds made of high-speed steel has been subject to many research activities. Existing approaches in the form of grinding and conventional milling processes do not achieve the surface quality desired for the forming operations and therefore often require manual polishing strategies afterward. This might lead to an unfavorable constitution for subsequent PVD coating processes causing delamination effects or poor adhesion of the wear-resistant coatings. To overcome these restrictions, meso- and micromilling are presented as promising approaches to polishing strategies with varying grain sizes. The processed topographies are correlated with the tribological properties determined in an adapted ring compression test using the deep drawing steel DC04. Additionally, the influence of the roughness profile as well as the induced residual stresses in the subsurface region are examined with respect to their influence on the adhesion of a wear-resistant CrAlN PVD coating. The results prove the benefits of micromilling in terms of a reduced friction factor in the load spectrum of Sheet-Bulk Metal Forming as well as an improved coating adhesion in comparison to metallographic finishing strategies, which can be correlated to the processed roughness profile and induced compressive residual stresses in the subsurface region. Full article
(This article belongs to the Special Issue Surface Integrity in Metals Machining)
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