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Innovative and Modern Technologies of Material Machining in Cutting and Abrasive Processes—Volume II

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (31 October 2023) | Viewed by 5377

Special Issue Editors

Faculty of Mechanical Engineering, Department of Production Engineering, Lublin University of Technology, 20-618 Lublin, Poland
Interests: cutting processes; surface metrology; tribology; maintenance; process diagnostics; additive manufacturing technologies
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Guest Editor
Faculty of Mechanical Engineering and Aeronautic, Rzeszow University of Technology, Powstancow Warszawy 12, 35-959 Rzeszow, Poland
Interests: additively manufactured polymers; additive manufacturing; rapid prototyping; aeronautical gears
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Machining and abrasive machining are among the most important production methods for machine parts. Machining accuracy and efficiency are crucial in many areas of the aviation and automotive industry. There is also growing interest in the machining of difficult-to-cut, advanced engineering materials such as titanium- and nickel-based alloys, tool steels, stainless steels, hardened steels, composites, shape memory alloys, cobalt–chromium alloys, magnesium-based alloys, etc. This requires the use of modern tool materials and abrasive components that are capable of effective cutting with high dimensional and shape accuracy. The development of tool materials and coatings applied to cutting edges is of vital importance in this area. In addition, the formation of specified properties and technological features of the surface layer after treatment poses many difficulties. Still, difficult-to-cut advanced engineering materials are favored for use in demanding applications due to their unique metallurgical properties, ability to operate at elevated temperatures, and high resistance to corrosion and fatigue, among other advantages. These materials are the most widely used in the aerospace, biomedical, and automotive industries. It must, however, be remembered that these new, difficult-to-cut materials are characterized by poor machinability, and their use implies high processing costs. Here, the optimization of machining operations and their modeling, as well as the ecological aspects of cutting, play a very important role. Therefore, the objective of this Special Issue is to publish original research and review papers in the field of the machinability of modern, difficult-to-cut engineering materials, especially those utilized in the aerospace, automotive, and biomedical industry, as well as in other sectors.

Potential topics in the field of cutting include, but are not limited to, the following:

  • Research on physical phenomena in the cutting process.
  • Modeling and simulation of the cutting process and machining operations.
  • Development of tool materials and coatings applied to cutting edges.
  • Design development of cutting tools and toolholders.
  • Optimization of machining operations and ecology in cutting.
  • Research and evaluation of surface layer properties.
  • Optimization of machining operations and their modeling.
  • Problems of cutting efficiency and quality in various areas of industry.
  • Cutting of difficult-to-cut materials.
  • Application of information technology in cutting processes.
  • Additive manufacturing techniques.
  • Burnishing technology.
  • Cutting process and system metrology.
  • Industrial design and Industry 4.0.

Potential topics in abrasive machining processes area include, but are not limited to, the following:

  • New technologies of abrasive machining processes.
  • Innovative solutions in the field of design and technology of abrasive tools.
  • Monitoring and optimization of abrasive and erosive machining processes.
  • Examination and evaluation of surface topography and physical properties of surface layer.
  • Modeling of abrasive machining operations and processes.
  • Micro burnishing processes, methods, and applications of electrochemical machining.
  • Hybrid abrasive machining processes.
  • Automation and robotization of surface treatment processes.
  • Ecology in abrasive machining.
  • Management and processing of post-grinding waste.
  • Formation of surface adhesive properties.

In this Special Issue, we invite researchers to contribute original research papers and review articles in this field of research.

Dr. Jerzy Józwik
Prof. Dr. Grzegorz Budzik
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. Materials 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 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

  • cutting
  • tool materials
  • surface morphology
  • surface energy
  • surface adhesion properties
  • electrical discharge machining
  • electrochemical machining
  • aviation, medicine, and automotive materials machining
  • ultraprecision and nonconventional manufacturing
  • ecology in manufacturing, burnishing, and insert coatings
  • additive manufacturing techniques
  • manufacturing processes
  • reverse engineering
  • materials science
  • CAD systems
  • metrology, industrial design, and Industry 4.0
  • machining processes
  • surface morphology
  • general metrology
  • aviation materials
  • construction of elements of internal combustion engines
  • construction of machines
  • toothed gears
  • fast prototyping

Related Special Issue

Published Papers (4 papers)

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Research

15 pages, 5484 KiB  
Article
Bioactivity, Cytotoxicity, and Tribological Studies of Nickel-Free Austenitic Stainless Steel Obtained via Powder Metallurgy Route
by Eliza Romanczuk-Ruszuk, Agnieszka Krawczyńska, Andrzej Łukaszewicz, Jerzy Józwik, Arkadiusz Tofil and Zbigniew Oksiuta
Materials 2023, 16(24), 7637; https://doi.org/10.3390/ma16247637 - 14 Dec 2023
Viewed by 802
Abstract
In the present study, the bioactivity, cytotoxicity, and tribological properties of a nickel-free austenitic stainless steel produced via the mechanical alloying of elemental iron, chromium, and manganese nitride powders following by hot isostatic pressing was investigated. Powders after 90 h of mechanical alloying [...] Read more.
In the present study, the bioactivity, cytotoxicity, and tribological properties of a nickel-free austenitic stainless steel produced via the mechanical alloying of elemental iron, chromium, and manganese nitride powders following by hot isostatic pressing was investigated. Powders after 90 h of mechanical alloying were consolidated via hot isostatic pressing at 1150 °C (1425 K) and heat treated at 1175 °C (1448 K) for 1 h in a vacuum with furnace cooling. Tribological tests were performed to determine the resistance of the as-received nickel-free steel. It was noticed that applying heat treatment after hot isostatic pressing decreases the average friction coefficient and wear rate of the austenitic steel. An immersion test in a simulated body fluid for 28 days at 37 ± 1 °C has been used to determine the biocompatibility of the tested material. The SEM-EDS analysis allowed us to characterise the morphology of the films and the elements of the steel on the thin-film layer. Elements typical of apatite (calcium and phosphorus) were detected on the surface of the sample. Cellular toxicity tests showed no significant toxic side effects for Saos-2 human osteosarcoma cells and the number of Saos-2 human osteosarcoma cells on the nickel-free steel was greater than on the 316LV grade steel. Full article
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29 pages, 15098 KiB  
Article
Modeling and Machine Learning of Vibration Amplitude and Surface Roughness after Waterjet Cutting
by Michał Leleń, Katarzyna Biruk-Urban, Jerzy Józwik and Paweł Tomiło
Materials 2023, 16(19), 6474; https://doi.org/10.3390/ma16196474 - 29 Sep 2023
Cited by 1 | Viewed by 810
Abstract
This study focused on analyzing vibrations during waterjet cutting with variable technological parameters (speed, vfi; and pressure, pi), using a three-axis accelerometer from SEQUOIA for three different materials: aluminum alloy, titanium alloy, and steel. Difficult-to-machine materials often require specialized [...] Read more.
This study focused on analyzing vibrations during waterjet cutting with variable technological parameters (speed, vfi; and pressure, pi), using a three-axis accelerometer from SEQUOIA for three different materials: aluminum alloy, titanium alloy, and steel. Difficult-to-machine materials often require specialized tools and machinery for machining; however, waterjet cutting offers an alternative. Vibrations during this process can affect the quality of cutting edges and surfaces. Surface roughness was measured by contact methods after waterjet cutting. A machine learning (ML) model was developed using the obtained maximum acceleration values and surface roughness parameters (Ra, Rz, and RSm). In this study, five different models were adopted. Due to the characteristics of the data, five regression methods were selected: Random Forest Regressor, Linear Regression, Gradient Boosting Regressor, LGBM Regressor, and XGBRF Regressor. The maximum vibration amplitude reached the lowest acceleration value for aluminum alloy (not exceeding 5 m/s2), indicating its susceptibility to cutting while maintaining a high surface quality. However, significantly higher acceleration amplitudes (up to 60 m/s2) were registered for steel and titanium alloy in all process zones. The predicted roughness parameters were determined from the developed models using second-degree regression equations. The prediction of vibration parameters and surface quality estimators after waterjet cutting can be a useful tool that for allows for the selection of the optimal abrasive waterjet machining (AWJM) technological parameters. Full article
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17 pages, 5122 KiB  
Article
Exploring the Relationship between Particulate Matter Emission and the Construction Material of Road Surface: Case Study of Highways and Motorways in Poland
by Magdalena Penkała, Wioletta Rogula-Kozłowska, Paweł Ogrodnik, Jan Stefan Bihałowicz and Natalia Iwanicka
Materials 2023, 16(3), 1200; https://doi.org/10.3390/ma16031200 - 31 Jan 2023
Cited by 5 | Viewed by 1285
Abstract
Road dust is an important inexhaustible source of particulate matter from traffic and the resuspension of finer particles carried by wind and traffic. The components of this material are of both natural and anthropogenic origin. Sources of particulate pollution are vehicles and road [...] Read more.
Road dust is an important inexhaustible source of particulate matter from traffic and the resuspension of finer particles carried by wind and traffic. The components of this material are of both natural and anthropogenic origin. Sources of particulate pollution are vehicles and road infrastructure. The work aimed to analyze the mass fraction of the finest fractions of road dust (<0.1 mm) collected from highways and expressways with asphalt and concrete surfaces. Sampling points were located in the central and southern parts of Poland. The research material was sieved on a sieve shaker. It has been proven that concrete pavement is less susceptible to abrasion than asphalt pavement. Particles formed under the influence of the erosion of asphalt and concrete belong to the fraction gathering coarser particles than the critical for this research fraction (<0.1 mm). It was found that limiting the area with sound-absorbing screens leads to the accumulation of fine road dust in this place, contrary to the space where are strong air drafts that remove smaller particles from the vicinity of the road. In general, the mass fraction of particles smaller than 100 μm in road dust was from 12.8% to 3.4% for asphalt surfaces and from 12.0% to 6.5% for concrete surfaces. Full article
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14 pages, 4031 KiB  
Article
Evaluation of Selected Properties of Dielectric Barrier Discharge Plasma Jet
by Michał Kwiatkowski, Piotr Terebun, Katarína Kučerová, Barbora Tarabová, Zuzana Kovalová, Aleksandra Lavrikova, Zdenko Machala, Karol Hensel and Joanna Pawłat
Materials 2023, 16(3), 1167; https://doi.org/10.3390/ma16031167 - 30 Jan 2023
Cited by 1 | Viewed by 1952
Abstract
In the technological processes requiring mild treatment, such as soft materials processing or medical applications, an important role is played by non-equilibrium plasma reactors with dielectric barrier discharge (DBD), that when generated in noble gases allows for the effective treatment of biological material [...] Read more.
In the technological processes requiring mild treatment, such as soft materials processing or medical applications, an important role is played by non-equilibrium plasma reactors with dielectric barrier discharge (DBD), that when generated in noble gases allows for the effective treatment of biological material at a low temperature. The aim of this study is to determine the operating parameters of an atmospheric pressure, radio-frequency DBD plasma jet reactor for the precise treatment of biological materials. The tested parameters were the shape of the discharge (its length and volume), current and voltage signals, as well as the power consumed by the reactor for various composition and flow rates of the working gas. To determine the applicability in medicine, the temperature, pH, concentrations of H2O2, NO2 and NO3 and Escherichia coli log reduction in the plasma treated liquids were determined. The obtained results show that for certain operating parameters, a narrow shape of plasma stream can generate significant amounts of H2O2, allowing for the mild decontamination of bacteria at a relatively low power of the system, safe for the treatment of biological materials. Full article
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