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Advances and Trends in Non-conventional, Abrasive and Precision Machining 2022
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Special Issue "Advances and Trends in Non-conventional, Abrasive and Precision Machining 2022"

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Advanced Manufacturing".

Deadline for manuscript submissions: 15 January 2024 | Viewed by 4281

Special Issue Editors

Prof. Dr. Mariusz Deja

E-Mail Website
Guest Editor
Department of Manufacturing and Production Engineering, Faculty of Mechanical Engineering, Gdańsk University of Technology, 80-233 Gdańsk, Poland
Interests: adaptive and dynamic process planning; modelling and developing new tools for abrasive processes; design for additive manufacturing DFAM
Special Issues, Collections and Topics in MDPI journals
Dr. Angelos P. Markopoulos

E-Mail Website
Guest Editor
Section of Manufacturing Technology, School of Mechanical Engineering, National Technical University of Athens, 15780 Athens, Greece
Interests: manufacturing technology; machining processes; non-conventional machining; modeling and simulation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The modern highly competitive industrial environment demands machining and production processes resulting in exceptional quality and precision. The general trend to design and manufacture more complicated mechanical components, along with the rapidly moving forward material science, raise the need to incorporate and develop new machining techniques in the manufacturing process. Nonconventional machining processes differ from conventional ones, as they utilize alternative types of energy, such as thermal, electrical, and chemical, to form or to remove material. Commonly, the energy source has high power density, while the process features prodigious accuracy, and the capability to produce and handle demanding shapes and geometries. Examples of nonconventional machining processes are electrical discharge machining (EDM), electrochemical machining (ECM), laser processing, and laser-assisted machining. Abrasive processes like grinding, lapping, polishing, and superfinishing are constantly developing and allow for obtaining a fine surface finish along with high efficiency.   

There is an increased scientific and commercial interest in in-depth understanding, and further development of the aforementioned nonconventional and precision machining processes. Research is moving forward through experimental studies, as well in the field of modeling and simulation, exploiting the increased available computational power. Multiphysics and multidisciplinary and multiscale modeling are powerful tools in the effort to optimize existing nonconventional precision machining processes, as well to develop novel ones. As their wider use by the industry swiftly grows, research has to be focused on them, not only due to the academic and scientific interest, but also for the possible financial gain.

This Special Issue aims at attracting researchers to present recent advances and technologies in the aforementioned fields, indicating the future trends for nonconventional precision machining processes.

Prof. Dr. Mariusz Deja
Dr. Angelos P. Markopoulos
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. Machines 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 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

  • laser processing/laser-assisted machining
  • high-density power machining
  • electrodischarge machining
  • electrochemical machining
  • abrasive processes
  • lapping/polishing/superfinishing
  • ultrasonic machining
  • water jet machining/abrasive water jet machining
  • burnishing
  • other nonconventional machining
  • precision machining
  • micro- and nanomachining
  • machine tools
  • modeling and simulation
  • surface quality and integrity
  • manufacturing systems
  • nanomaterials

Published Papers (4 papers)

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Research

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Article
A New Slurry for Photocatalysis-Assisted Chemical Mechanical Polishing of Monocrystal Diamond
by
Junyong Shao
,
Yanjun Zhao
,
Jianhui Zhu
,
Zewei Yuan
,
Haiyang Du
and
Quan Wen
Machines 2023, 11(6), 664; https://doi.org/10.3390/machines11060664 - 20 Jun 2023
Viewed by 719
Abstract
Diamond needs to have a perfectly smooth surface due to the growing requirements in the fields of electronic semiconductors, optical windows and high-fidelity loudspeakers. However, the polishing of diamonds is highly challenging due to their exceptional hardness and chemical stability. In this study, [...] Read more.
Diamond needs to have a perfectly smooth surface due to the growing requirements in the fields of electronic semiconductors, optical windows and high-fidelity loudspeakers. However, the polishing of diamonds is highly challenging due to their exceptional hardness and chemical stability. In this study, a new polishing slurry is prepared for the proposed photocatalysis-assisted chemical mechanical polishing (PCMP) approach to obtain an ultra-smooth surface for large-area diamond. The analyses and experimental findings revealed the significance of the photocatalyst, abrasive, electron capture agent and pH regulator as essential components of the PCMP slurry. TiO2 with a 5 nm pore size and P25 TiO2 possess improved photocatalysis efficiency. Moreover, diamond removal is smooth under the acidic environment of H3PO4 due to the high oxidation–reduction potential (ORP) of the slurry, and, during the methyl orange test, P25 TiO2 exhibits reasonable photocatalytic effects. Moreover, in 8 h, a smooth surface free of mechanical scratches can be obtained by reducing the surface roughness from Ra 33.6 nm to Ra 2.6 nm. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining 2022)
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Article
Gear Wheel Finishing with Abrasive Brushing Tools to Improve the Surface Quality of Tooth Flanks for the Industrial Application
by
Bernhard Gülzow
and
Eckart Uhlmann
Machines 2022, 10(12), 1220; https://doi.org/10.3390/machines10121220 - 15 Dec 2022
Cited by 1 | Viewed by 1060
Abstract
A high surface quality of tooth flanks can improve the service life and the performance of gears, as well as reduce acoustic emissions. However, high demands on the gear geometry pose a challenge for the finishing of tooth flank surfaces because the dimensional [...] Read more.
A high surface quality of tooth flanks can improve the service life and the performance of gears, as well as reduce acoustic emissions. However, high demands on the gear geometry pose a challenge for the finishing of tooth flank surfaces because the dimensional accuracy that can be achieved with modern grinding processes must not be impaired by the finishing process. A preceding study has shown fundamentally that profiled abrasive brushing tools can be used to improve the quality of individual tooth flank surfaces. Due to the integration into the grinding machine, it represents a promising alternative to common finishing applications. Before the process can be used in an industrial environment, process reliability and tool life must be examined. For this purpose, complete reference gearwheels (39 × 10) were finished with the brushing tools. It could be shown that the surface roughness can be reliably reduced by ΔRa ≈ 0.2 µm by using a single brush for an entire gearwheel without changing the gear geometry. In addition to the influence of the tool specifications on the work result, the influence of the initial roughness after grinding was considered in particular. It was found that the achievable surface roughness depends significantly on the depth of the grinding grooves, as these are retained as desired, while the roughness peaks are fully smoothed. Furthermore, a device for the machine-integrated profiling and dressing of brushing tools was successfully designed, implemented, and tested. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining 2022)
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Article
Prediction of the Roughness Reduction in Centrifugal Disc Finishing of Additive Manufactured Parts Based on Discrete Element Method
by
Marco Kopp
and
Eckart Uhlmann
Machines 2022, 10(12), 1151; https://doi.org/10.3390/machines10121151 - 01 Dec 2022
Viewed by 884
Abstract
One major drawback of additive manufacturing is the poor surface quality of parts, which negatively affects mechanical and tribological properties. Therefore, a surface finishing is necessary in most cases. Due to a high material removal rate, centrifugal disc finishing is a promising mass [...] Read more.
One major drawback of additive manufacturing is the poor surface quality of parts, which negatively affects mechanical and tribological properties. Therefore, a surface finishing is necessary in most cases. Due to a high material removal rate, centrifugal disc finishing is a promising mass finishing operation for an effective surface finishing of additive manufactured parts. However, due to machining the workpieces in a freely movable manner, the process is hardly controllable, and the process design is often based on time-consuming and cost-intensive trial-and-error approaches. Especially when it comes to the machining of complex-shaped workpieces, finishing results are barely predictable. Therefore, the aim of this study is to set up a numerical simulation of the centrifugal disc finishing based on the Discrete Element Method (DEM) to predict finishing results. A procedure to determine the required DEM input parameters is presented and the simulation was validated using a freely movable force sensor. The results of the finishing experiments with additive manufactured workpieces made of Ti-6Al-4V were correlated with the simulated results. The derived correlation was used to predict local differences in the roughness reduction, which occurred when finishing workpieces with a limited accessibility to the surface. As a result, it is concluded that the complex relationship between the type of media, the accessibility to the surface, and the achievable finishing results can be modeled using the DEM. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining 2022)
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Communication
Theoretical Assessment of the Role of Bond Material during Grinding of Superhard Materials with Diamond Wheels
by
János Kundrák
,
Vladimir Fedorovich
,
Angelos P. Markopoulos
,
Ivan Pyzhov
and
Yevgeniy Ostroverkh
Machines 2022, 10(7), 543; https://doi.org/10.3390/machines10070543 - 05 Jul 2022
Viewed by 1045
Abstract
The grinding of superhard materials poses an important challenge to manufacturing industry, due to the increased wear and the high possibility of fracture of both the wheel and workpiece material. Various strategies have been proposed for effective grinding of these materials, but further [...] Read more.
The grinding of superhard materials poses an important challenge to manufacturing industry, due to the increased wear and the high possibility of fracture of both the wheel and workpiece material. Various strategies have been proposed for effective grinding of these materials, but further research is still required, especially in cases in which the hardness of the wheel and the workpiece are almost equal. In this study, the role of the bond of a diamond grinding wheel during the processing of superhard materials, such as synthetic diamond, is investigated using theoretical models and FE simulation. Six different types of bonds are studied and the effect of their properties on the stress distribution of workpiece material is determined. Results indicate that even a slight increase in elastic modulus can affect considerably the stress state of the workpiece, directly affecting the critical embedding value of grains into the bond, something that can alter considerably the efficiency of grinding superhard materials. Thus, grinding wheels with bonds of high elastic modulus should be selected in order to increase grain retention, increase processing efficiency, and reduce specific consumption even at higher cross feeds and wheel speeds. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining 2022)
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