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Special Issue "Advanced Machining Technology for Modern Engineering Materials"

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

Deadline for manuscript submissions: 20 December 2023 | Viewed by 12423

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Special Issue Editors

Dr. Muthuramalingam Thangaraj

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Department of Mechatronics Engineering, SRM Institute of Science and Technology, Kattankulathur Campus, Chennai 603203, Tamilnadu, India
Interests: mechatronics; unconventional machining; optimization; manufacturing automation; printed electronics

Dr. Beata Leszczyńska-Madej

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Guest Editor

Department of Materials Science and Non-Ferrous Metals Engineering, Faculty of Non-Ferrous Metals, AGH University of Science and Technology, 30-059 Cracow, Poland
Interests: microstructure characterization; materials science; friction stir processes; tribology; metal-matrix composites (MMCs); powder metallurgy; severe plastic deformation (SPD); light metals and alloys; surface engineering; bearing alloys
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Dr. Angelos P. Markopoulos

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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

Panagiotis Karmiris-Obratański

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Guest Editor Assistant

Department of Manufacturing Systems, Faculty of Mechanical Engineering and Robotics, AGH University of Science and Technology, 30-059 Cracow, Poland
Interests: metal cutting and cutting tools; non-convectional machining; surface topography; surface metrology; materials science; optimization of process parameters; friction stir processes; additive manufacturing

Special Issue Information

Dear Colleagues,

Advances in material science have given an unprecedented boost in engineering. Materials with exceptional properties (mechanical, thermal, and chemical) have been developed, including super and memory alloys, composite materials, and biocompatible materials. At the same time, the machining industry must follow these advances, coming up with new machining methods and processes, as well as effective ways of studying those materials at the macro-, meso-, and microscale. Therefore, the current Special Issue aims to provide a forum for scientists’ research on the machinability and the mechanical properties of advanced materials. We will host experimental and/or computational studies concerning conventional, non-conventional, and hybrid machining, and additive methods of advanced materials. Additionally, research about advanced techniques in the study of materials, which give an inside view and a better understanding of the fundamental mechanisms, are welcome. Finally, review articles about the topics mentioned above are encouraged.

Dr. Muthuramalingam Thangaraj
Prof. Dr. Beata Leszczyńska-Madej
Dr. Angelos P. Markopoulos
Guest Editors

Panagiotis Karmiris-Obratański
Guest Editor Assistant

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

nanomaterials/nanocomposites
laser processing/laser-assisted machining
ultrasonic machining
friction stir processing/welding
microstructure modeling
multiscale modeling
optimization
hydrogen embrittlement
additive manufacturing
polymers and leather
surface texture/topography

Published Papers (12 papers)

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Research

17 pages, 5581 KiB

Open AccessArticle

Optimization of Cutting Parameters for Deep Hole Boring of Ti-6Al-4V Deep Bottle Hole

Wanzhong Li

Huan Zheng

and

Yazhou Feng

Materials 2023, 16(15), 5286; https://doi.org/10.3390/ma16155286 - 27 Jul 2023

Viewed by 477

Abstract

In this study, the cutting parameters for machining deep bottle holes (deep holes with complex profiles and length-to-diameter ratio greater than 10) were optimized based on cutting simulation, a regression analysis genetic algorithm, and experimental validation. The influence of cutting parameters on cutting force and cutting temperature was analyzed using the response surface method (RSM), and the regression prediction model of cutting parameters with cutting force and most cutting temperature was established. Based on this model, multi-objective optimization of cutting force F_x and material removal rate Q was carried out based on a genetic algorithm, and a set of optimal cutting parameters (v = 139.41 m/min, a_p = 1.12 mm, f = 0.27 mm/rev) with low cutting force and high material removal rate were obtained. Finally, based on the optimal cutting parameters, the machining of TC4 deep bottle holes with a length-to-diameter (L/D) ratio of 36.36 and a roughness of Ra 3.2 µm was accomplished through a deep hole boring experiment, which verified the feasibility of the selected cutting parameters and provided a certain reference for the machining of this type of parts. Full article

(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials)

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23 pages, 22434 KiB

Open AccessArticle

Structural Features of Fatigue Crack Propagation of a Forging Die Made of Chromium–Molybdenum–Vanadium Tool Steel on Its Durability

and

Materials 2023, 16(12), 4223; https://doi.org/10.3390/ma16124223 - 07 Jun 2023

Cited by 2 | Viewed by 685

Abstract

The paper presents the results of tests on a die insert made of non-standardised chrome-molybdenum–vanadium tool steel used during pre-forging, the life of which was 6000 forgings, while the average life for such tools is 8000 forgings. It was withdrawn from production due to intensive wear and premature breakage. In order to determine the causes of increased tool wear, a comprehensive analysis was carried out, including 3D scanning of the working surface; numerical simulations, with particular emphasis on cracking (according to the C-L criterion); and fractographic and microstructural tests. The results of numerical modelling in conjunction with the obtained results of structural tests allowed us to determine the causes of cracks in the working area of the die, which were caused by high cyclical thermal and mechanical loads and abrasive wear due to intensive flow of the forging material. It was found that the resulting fracture initiated as a multi-centric fatigue fracture continued to develop as a multifaceted brittle fracture with numerous secondary faults. Microscopic examinations allowed us to evaluate the wear mechanisms of the insert, which included plastic deformation and abrasive wear, as well as thermo-mechanical fatigue. As part of the work carried out, directions for further research were also proposed to improve the durability of the tested tool. In addition, the observed high tendency to cracking of the tool material used, based on impact tests and determination of the K_1C fracture toughness factor, led to the proposal of an alternative material characterised by higher impact strength. Full article

(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials)

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22 pages, 10179 KiB

Open AccessArticle

Study on the Effect of Inter-Layer Cooling Time on Porosity and Melt Pool in Inconel 718 Components Processed by Laser Powder Bed Fusion

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Materials 2023, 16(11), 3920; https://doi.org/10.3390/ma16113920 - 24 May 2023

Cited by 3 | Viewed by 1051

Abstract

This paper investigates the effects on the material microstructure of varying the Inter-Layer Cooling Time (ILCT) during the printing process in laser powder bed fusion (L-PBF) multi-laser machines. Despite these machines allowing higher productivity rates compared to single laser machines, they are affected by lower ILCT values, which could be critical for material printability and microstructure. The ILCT values depend both on the process parameter sets and design choices for the parts and play an important role in the Design for Additive Manufacturing approach in L-PBF process. In order to identify the critical range of ILCT for this working condition, an experimental campaign is presented on the nickel-based superalloy Inconel 718, which is widely used for the printing of turbomachinery components. The effect of ILCT on the microstructure of the material is evaluated in terms of porosity and melt pool analysis on printed cylinder specimens, considering ILCT decreasing and increasing in the range of 22 to 2 s. The experimental campaign shows that an ILCT of less than 6 s introduces criticality in the material microstructure. In particular, at an ILCT value of 2 s, widespread keyhole porosity (close to 1‰) and critical and deeper melt pool (about 200 microns depth) are measured. This variation in melt pool shape indicates a change in the powder melting regime and, consequently, modifications of the printability window promoting the expansion of the keyhole region. In addition, specimens with geometry obstructing the heat flow have been studied using the critical ILCT value (2 s) to evaluate the effect of the surface-to-volume ratio. The results show an enhancement of the porosity value (about 3‰), while this effect is limited for the depth of the melt pool. Full article

(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials)

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14 pages, 7040 KiB

Open AccessArticle

Optimization of Friction Stir Spot Welding Process Using Bonding Criterion and Artificial Neural Network

Deok Sang Jo

Parviz Kahhal

and

Ji Hoon Kim

Materials 2023, 16(10), 3757; https://doi.org/10.3390/ma16103757 - 16 May 2023

Viewed by 640

Abstract

The objectives of this study were to analyze the bonding criteria for friction stir spot welding (FSSW) using a finite element analysis (FEA) and to determine the optimal process parameters using artificial neural networks. Pressure-time and pressure-time-flow criteria are the bonding criteria used to confirm the degree of bonding in solid-state bonding processes such as porthole die extrusion and roll bonding. The FEA of the FSSW process was performed with ABAQUS-3D Explicit, with the results applied to the bonding criteria. Additionally, the coupled Eulerian–Lagrangian method used for large deformations was applied to deal with severe mesh distortions. Of the two criteria, the pressure-time-flow criterion was found to be more suitable for the FSSW process. Using artificial neural networks with the bonding criteria results, process parameters were optimized for weld zone hardness and bonding strength. Among the three process parameters used, tool rotational speed was found to have the largest effect on bonding strength and hardness. Experimental results were obtained using the process parameters, and these results were compared to the predicted results and verified. The experimental value for bonding strength was 4.0 kN and the predicted value of 4.147 kN, resulting in an error of 3.675%. For hardness, the experimental value was 62 Hv, the predicted value was 60.018 Hv, and the error was 3.197%. Full article

(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials)

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22 pages, 12563 KiB

Open AccessArticle

Investigation and Optimization of Effects of 3D Printer Process Parameters on Performance Parameters

and

Materials 2023, 16(9), 3392; https://doi.org/10.3390/ma16093392 - 26 Apr 2023

Cited by 3 | Viewed by 986

Abstract

Professionals in industries are making progress in creating predictive techniques for evaluating critical characteristics and reactions of engineered materials. The objective of this investigation is to determine the optimal settings for a 3D printer made of acrylonitrile butadiene styrene (ABS) in terms of its conflicting responses (flexural strength (FS), tensile strength (TS), average surface roughness (Ra), print time (T), and energy consumption (E)). Layer thickness (LT), printing speed (PS), and infill density (ID) are all quantifiable characteristics that were chosen. For the experimental methods of the prediction models, twenty samples were created using a full central composite design (CCD). The models were verified by proving that the experimental results were consistent with the predictions using validation trial tests, and the significance of the performance parameters was confirmed using analysis of variance (ANOVA). The most crucial element in obtaining the desired Ra and T was LT, whereas ID was the most crucial in attaining the desired mechanical characteristics. Numerical multi-objective optimization was used to achieve the following parameters: LT = 0.27 mm, ID = 84 percent, and PS = 51.1 mm/s; FS = 58.01 MPa; TS = 35.8 MPa; lowest Ra = 8.01 m; lowest T = 58 min; and E = 0.21 kwh. Manufacturers and practitioners may profit from using the produced numerically optimized model to forecast the necessary surface quality for different aspects before undertaking trials. Full article

(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials)

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15 pages, 4070 KiB

Open AccessArticle

Performance Evaluation of Input Power of Diode Laser on Machined Leather Specimen in Laser Beam Cutting Process

Tamer Khalaf

Muthuramalingam Thangaraj

and

Mohamed Kamaleldin Aboudaif

Materials 2023, 16(6), 2416; https://doi.org/10.3390/ma16062416 - 17 Mar 2023

Cited by 1 | Viewed by 924

Abstract

Numerous industries, including footwear, handicrafts, and the automobile industry, utilize leather materials. The main goal of this study was to investigate the effect of input power of the diode laser in laser cutting on vegetable chrome tanned buffalo leather to enhance the cutting process. In the present investigation, carbonization, kerf width, and material removal rate (MRR) were taken as performance measures. The diode-based laser beam machining was designed and fabricated with 2.5 W, 5.5 W, and 20 W diode laser to cut vegetable chrome tanned leather. The high-intensity 20 W diode laser produced lower carbonization, lower kerf width, and higher material removal rate compared with the 2.5 W and 5.5 W diodes. This improved performance was due to the adjustable features associated with this diode laser actuation in the form of circular shape with adjustable diameter. A high power with a lower spot size under pulsed mode can produce higher power density. Since a higher power density can establish less interaction time, it produces lower carbonization. Due to the ability of the 20 W diode laser driver to control the beam shape and size, it could produce a lower kerf width and higher MRR. The optimal parameters for cutting chrome vegetable tanned cow leather were a standoff distance of 18 mm, feed rate of 200 mm/min, and duty cycle of 70%. Full article

(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials)

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20 pages, 6357 KiB

Open AccessArticle

Effect of Cutting Fluid on Machined Surface Integrity and Corrosion Property of Nickel Based Superalloy

and

Materials 2023, 16(2), 843; https://doi.org/10.3390/ma16020843 - 15 Jan 2023

Viewed by 958

Abstract

Superalloy parts place high demands on machined surface integrity and serviceability. In the machining process of superalloys, the cutting fluid is usually used to improve the machining performance. Cutting fluids with cooling and lubrication functions have a relatively large effect on the surface microstructure and residual stress as well. The corrosion damage caused by cutting fluid to the machined surface, during machining and residual, are also worth considering. In this paper, the machining performance of typical binary Ni Cr solid solution, age-hardened, nickel-based superalloy NiCr20TiAl T6, under two commonly used cutting fluids, Blasocut and E709, was analyzed, including cutting performance, surface quality, machining surface corrosion characteristics, and so on. The results showed that the surface residual stress could be improved by adding both cutting fluids compared with the deionized water. Blasocut had better lubrication properties, which could reduce friction and heat production. Pitting holes were found on the polished surface after 45 days with E709 cutting fluid, which was more corrosive than Blasocut. According to this research, a reasonable cutting fluid can be selected to reduce the surface corrosion and improve the service life and performance of parts. Full article

(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials)

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25 pages, 6705 KiB

Open AccessArticle

Helical Milling of CFRP/Ti6Al4V Stacks Using Nano Fluid Based Minimum Quantity Lubrication (NF-MQL): Investigations on Process Performance and Hole Integrity

Kiran Mughal

Mohammad Pervez Mughal

Muhammad Umar Farooq

Muhammad Qaiser Saleem

and

Rodolfo Haber Guerra

Materials 2023, 16(2), 566; https://doi.org/10.3390/ma16020566 - 06 Jan 2023

Cited by 2 | Viewed by 973

Abstract

The structural components in the aeronautical industry require CFRP/Ti6Al4V stacks to be processed together, which results in poor hole integrity due to the thermal properties of the materials and challenges related to processability. These challenges include quality variation of the machined holes because of the limitations in process properties. Therefore, a novel solution through helical milling is investigated in the study using nano fluid based minimum quantity lubrication (NF-MQL). The analysis of variance shows, for Ti6Al4V, eccentricity (PCR = 28.56%), spindle speed (Ti) (PCR = 42.84%), and tangential feed (PCR = 8.61%), and for CFRP, tangential feed (PCR = 40.16%), spindle speed (PCR = 28.75%), and eccentricity (PCR = 8.41%) are the most significant parameters for diametric error. Further on, the rise in the circularity error is observed because of prolonged tool engagement at a higher value of tangential feed. Moreover, the surface roughness of Ti was reduced with an increasing percentage of MoS₂ in the lubricant. The spindle speed (37.37%) and lubricant (45.76%) have a potential influence on the processing temperature, as evident in the analysis of variance. Similarly, spindle speed Ti (61.16%), tangential feed (23.37%), and lubrication (11.32%) controlled flank wear, which is critical to tool life. Moreover, the concentration of MoS₂ decreased edge wear from ~105 µm (0.5% concentration) to ~70 µm (1% concentration). Thorough analyses on process performance in terms of hole accuracy, surface roughness, processing temperature, and tool wear are carried out based on the physical science of the process for cleaner production. The NF-MQL has significantly improved process performance and hole integrity. Full article

(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials)

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17 pages, 5144 KiB

Open AccessArticle

Design of Real-Time Extremum-Seeking Controller-Based Modelling for Optimizing MRR in Low Power EDM

Mohamed Rabik Mohamed Ismail

Muthuramalingam Thangaraj

Panagiotis Karmiris-Obratański

Emmanouil Papazoglou

and

Nikolaos Karkalos

Materials 2023, 16(1), 434; https://doi.org/10.3390/ma16010434 - 03 Jan 2023

Cited by 5 | Viewed by 1051

Abstract

Electric discharge machining (EDM) is one of the non-conventional machining processes that supports machining for high-strength and wear-resistant materials. It is a challenging task to select the process parameters in real-time to maximize the material removal rate since real-time process trials are expensive and the EDM process is stochastic. For the ease of finding process parameters, a modelling of the EDM process is proposed. Due to the non-linear relationship between the material removal rate (MRR) and discharge time, a model-free adaptive extremum-seeking controller (ESC) is proposed in the feedback path of the EDM process for finding an optimal value of the discharge time at which the maximum material removal rate can be achieved. The results of the model show a performance that is closer to the actual process by choosing steel workpieces and copper electrodes. The proposed model offers a lower error rate when compared with actual experimental process data. When compared to manual searching for an optimal point, extreme seeking online searching performed better as per the experimental results. It was observed that the experimental validation also proved that the ESC can produce a large MRR by tracking the extremum control. The present study has been limited to only the MRR, but it is also possible to implement such algorithms for more than one response parameter optimization in future studies. In such cases the performance measures of the process could be further enhanced, which could be used for a real-time complex die- and mold-making process using EDM. Full article

(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials)

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24 pages, 20542 KiB

Open AccessArticle

Investigation of the Effect of ECAP Parameters on Hardness, Tensile Properties, Impact Toughness, and Electrical Conductivity of Pure Cu through Machine Learning Predictive Models

Mahmoud Shaban

Mohammed F. Alsharekh

Fahad Nasser Alsunaydih

Abdulrahman I. Alateyah

and

Materials 2022, 15(24), 9032; https://doi.org/10.3390/ma15249032 - 17 Dec 2022

Cited by 4 | Viewed by 1287

Abstract

Copper and its related alloys are frequently adopted in contemporary industry due to their outstanding properties, which include mechanical, electrical, and electronic applications. Equal channel angular pressing (ECAP) is a novel method for producing ultrafine-grained or nanomaterials. Modeling material design processes provides exceptionally efficient techniques for minimizing the efforts and time spent on experimental work to manufacture Cu or its associated alloys through the ECAP process. Although there have been various physical-based models, they are frequently coupled with several restrictions and still require significant time and effort to calibrate and enhance their accuracies. Machine learning (ML) techniques that rely primarily on data-driven models are a viable alternative modeling approach that has recently achieved breakthrough achievements. Several ML algorithms were used in the modeling training and testing phases of this work to imitate the influence of ECAP processing parameters on the mechanical and electrical characteristics of pure Cu, including the number of passes (N), ECAP die angle (φ), processing temperature, and route type. Several experiments were conducted on pure commercial Cu while altering the ECAP processing parameters settings. Linear regression, regression trees, ensembles of regression trees, the Gaussian process, support vector regression, and artificial neural networks are the ML algorithms used in this study. Model predictive performance was assessed using metrics such as root-mean-squared errors and R² scores. The methodologies presented here demonstrated that they could be effectively used to reduce experimental effort and time by reducing the number of experiments runs required to optimize the material attributes aimed at modeling the ECAP conditions for the following performance characteristics: impact toughness (I_T), electrical conductivity (E_C), hardness, and tensile characteristics of yield strength (σ_y), ultimate tensile strength (σ_u), and ductility (D_u) Full article

(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials)

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16 pages, 4160 KiB

Open AccessArticle

Self-Propelled Rotary Tools in Hard Turning: Analysis and Optimization via Finite Element Models

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Materials 2022, 15(24), 8781; https://doi.org/10.3390/ma15248781 - 08 Dec 2022

Cited by 1 | Viewed by 1108

Abstract

This study investigates self-propelled rotary tool (SPRT) performance in hard turning using 3D finite element (FE) models. The FE models developed in this study are based on coupled temperature-displacement analysis using an explicit time-integration scheme. The developed FE models can predict chip morphology, cutting forces, tool and workpiece stresses and temperatures. For model verification, hard turning experiments were conducted using an SPRT on AISI 4340 bars. Cutting forces and maximum tool–chip interface temperatures were recorded and compared with the model findings. The effects of different process parameters were analyzed and discussed using the developed FE models. The FE models were run with a central composite design (CCD-25) matrix with four input variables, i.e., the cutting speed, the feed rate, the depth of the cut and the inclination angle. Response surfaces based on the Gaussian process were generated for each performance variable in order to predict design points not available in the original design of the experiment matrix. An optimization study was carried out to minimize tool stress and temperature while setting limits for the material removal rate (MRR) and specific cutting energy for the process. Optimized processes were found with moderate cutting speeds and feed rates and high depths of cut and inclination angles. Full article

(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials)

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15 pages, 4949 KiB

Open AccessArticle

BTA Deep Hole Vibration Drilling for Nickel-Based Alloys: Cooling Patterns and Cutter Tooth Wear Mechanisms

and

Materials 2022, 15(22), 8178; https://doi.org/10.3390/ma15228178 - 17 Nov 2022

Cited by 2 | Viewed by 924

Abstract

The high cutting temperature and poor thermal diffusion efficiency of nickel-based alloys during deep hole machining have become technical challenges in the hole machining field. In this paper, a finite element simulation model of Inconel-718 BTA ordinary drilling and vibration drilling processes was established by using Deform-3D finite element simulation software. The variations in the temperatures of the tool teeth and the workpiece at different positions of the nickel-based alloy under ordinary drilling and vibration drilling were investigated. Additionally, the wear pattern of each tool tooth under the two drilling methods was further analyzed by building an experimental platform for workpiece temperature detection, which reveals the wear and cooling mechanism of nickel-based alloy BTA deep hole drilling. The results show that the average temperatures of the external, intermediate, and central teeth were reduced by 18.1%, 21.1%, and 17.8%, respectively, during vibration drilling. In addition, the workpiece hole wall and hole bottom temperatures were reduced by 5.7% and 4.6%, respectively. To conclude, the experimental tests were consistent with the simulated temperature trends. BTA vibration drilling optimizes the heat exchange conditions between the cutter teeth and the workpiece during the drilling of nickel-based alloys, which effectively reduces the cutting temperature and, thus, improves the wear resistance of the cutter teeth. Full article

(This article belongs to the Special Issue Advanced Machining Technology for Modern Engineering Materials)

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