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Metals
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Modelling and Simulation in Metal Cutting and Machining Process
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Modelling and Simulation in Metal Cutting and Machining Process

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Computation and Simulation on Metals".

Deadline for manuscript submissions: 31 August 2024 | Viewed by 7715

Special Issue Editors

Prof. Dr. Adel Abbas

E-Mail Website
Guest Editor
Mechanical Engineering Department, King Saud University, Riyadh 11421, Saudi Arabia
Interests: manufacturing; CNC machines; CAD/CAM/CAE
Dr. Ahmed Elkaseer

E-Mail Website
Guest Editor
Institute for Automation and Applied Informatics, Karlsruhe Institute of Technology, 76344 Eggenstein-Leopoldshafen, Germany
Interests: machining; modelling and optimization of manufacturing processes; 3D functional printing; hybrid additive and subtractive processes
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The arrival of Industry 4.0 has paved the way for a radical transformation of manufacturing into more intelligent, highly dynamic and interactive systems, in which the modelling and simulation of manufacturing processes play a key role in such new production paradigms. With its high potential to process numerous engineering materials, metal cutting/machining is considered a key enabling technology for a wide range of applications. Nevertheless, it is a complex material removal process, in which the cutting mechanism is highly dependent on a large number of process parameters. Accordingly, the precise modelling and simulation of metal machining helps improve the process responses in terms of economics and product quality. In this context, this Special Issue aims to collect a broad spectrum of cutting-edge and original research and review studies focused on the modelling and simulation of metal cutting processes and related subjects.

Prof. Dr. Adel Abbas
Dr. Ahmed Elkaseer
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. Metals 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

  • modelling and/or simulation of conventional and high-precision machining
  • modelling and/or simulation of micro-machining
  • modelling and/or simulation of difficult-to-cut (superalloys) machining
  • data-driven process improvement
  • optimisation of machining processes
  • numerical modelling and simulation of machining processes
  • statistical-based modelling and optimization of metal machining
  • artificial intelligence and machine learning for enhanced machining processes.

Published Papers (4 papers)

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Research

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15 pages, 3242 KiB  
Article
Processing of Al/SiC/Gr Hybrid Composite on EDM by Different Electrode Materials Using RSM-COPRAS Approach
by Adel T. Abbas, Neeraj Sharma, Zeyad A. Alsuhaibani, Vishal S. Sharma, Mahmoud S. Soliman and Rakesh Chandmal Sharma
Metals 2023, 13(6), 1125; https://doi.org/10.3390/met13061125 - 15 Jun 2023
Cited by 10 | Viewed by 1229
Abstract
The present research used the stir-casting method to develop an Al-based composite. The developed composite exhibited challenges while being processed on conventional machining. Thus, a non-traditional machining process was opted to process the composite. The machining variables selected for the current research were [...] Read more.
The present research used the stir-casting method to develop an Al-based composite. The developed composite exhibited challenges while being processed on conventional machining. Thus, a non-traditional machining process was opted to process the composite. The machining variables selected for the current research were the pulse off time (Toff), pulse on time (Ton), servo voltage (SV), current (I), and tool electrode. Three tool electrodes (SS-304, copper, and brass) were used to process the developed composite (Al/SiC/Gr). The experimental plan was designed using response surface methodology (RSM). The output responses recorded for the analysis were the material removal rate (MRR) and tool wear rate (TWR). The obtained data was optimized using complex proportional assessment (COPRAS) and machine learning methods. The optimized settings predicted by the RSM–COPRAS method were Ton: 60 µs; Toff: 60 µs; SV: 7 V; I: 12 A; and tool: brass. The maximum MRR and TWR at the suggested settings were 1.11 g/s and 0.0114 g/s, respectively. A morphological investigation of the machined surface and tool surface was conducted with scanning electron microscopy. The morphological examination of the surface (machined) presented the presence of cracks, lumps, etc. Full article
(This article belongs to the Special Issue Modelling and Simulation in Metal Cutting and Machining Process)
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19 pages, 7214 KiB  
Article
Investigation and Statistical Analysis for Optimizing Surface Roughness, Cutting Forces, Temperature, and Productivity in Turning Grey Cast Iron
by Magdy M. El Rayes, Adel T. Abbas, Abdulhamid A. Al-Abduljabbar, Adham E. Ragab, Faycal Benyahia and Ahmed Elkaseer
Metals 2023, 13(6), 1098; https://doi.org/10.3390/met13061098 - 10 Jun 2023
Cited by 1 | Viewed by 970
Abstract
This paper investigated the influence of cutting parameters, including feed rate, cutting speed, tool nose radius, and wet or dry cutting conditions, on the resultant force, cutting edge/workpiece temperature, and surface roughness when turning grey cast iron. Results showed that increasing the feed [...] Read more.
This paper investigated the influence of cutting parameters, including feed rate, cutting speed, tool nose radius, and wet or dry cutting conditions, on the resultant force, cutting edge/workpiece temperature, and surface roughness when turning grey cast iron. Results showed that increasing the feed rate increased the resultant force, cutting temperature, and surface roughness. At the same time, increasing the cutting speed and nose radius increased the cutting temperature, which in turn reduced the resultant force. For practical applications, basic mathematical calculations based on the sole effect of each parameter on the output of the experiments were used to estimate the extent of percentage increase in cutting temperature due to increasing feed rate, cutting speed, and nose radius. Similarly, the same approach was used to estimate the effect of increasing feed rate, cutting speed, and nose radius on average surface roughness. Results showed that increasing the feed rate increases the cutting temperature by 5 to 11% depending on the nose radius and cutting speed. On the other hand, increasing the cutting speed was found to have limited effect on cutting temperature with small nose radius whereas this effect increases with increasing the nose radius reaching about 11%. Increasing the nose radius also increases the cutting temperature, depending mainly on cutting speed, reaching a maximum of 21% at higher cutting speeds. Results also showed that increasing the feed rate increased the average surface roughness considerably to about 120% at high cutting speeds and a large nose radius. On the other hand, increasing the cutting speed and nose radius reduced the surface roughness (i.e., improved surface quality) by a maximum of 29 and 23%, respectively. In order to study the combined effects of the cutting parameters on the three responses, namely, the resultant cutting force, cutting temperature, and surface roughness, full factorial design and ANOVA were used, where it was found to be in good agreement with mathematical calculations. Additionally, the desirability function optimization tool was used to minimize the measured responses whilst maximizing the material removal rate. Full article
(This article belongs to the Special Issue Modelling and Simulation in Metal Cutting and Machining Process)
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14 pages, 1931 KiB  
Article
An Approach to Reduce Thermal Damages on Grinding of Bearing Steel by Controlling Cutting Fluid Temperature
by Raphael Lima de Paiva, Rodrigo de Souza Ruzzi and Rosemar Batista da Silva
Metals 2021, 11(10), 1660; https://doi.org/10.3390/met11101660 - 19 Oct 2021
Cited by 3 | Viewed by 2385
Abstract
The use of cutting fluid is crucial in the grinding process due to the elevated heat generated during the process which typically flows to the workpiece and can adversely affect its integrity. Considering the conventional technique for cutting fluid application in grinding (flood), [...] Read more.
The use of cutting fluid is crucial in the grinding process due to the elevated heat generated during the process which typically flows to the workpiece and can adversely affect its integrity. Considering the conventional technique for cutting fluid application in grinding (flood), its efficiency is related to certain factors such as the type of fluid, nozzle geometry/positioning, flow rate and coolant concentration. Another parameter, one which is usually neglected, is the cutting fluid temperature. Since the heat exchange between the cutting fluid and workpiece increases with the temperature difference, controlling the cutting fluid temperature before its application could improve its cooling capability. In this context, this work aimed to analyze the surface integrity of bearing steel (hardened SAE 52100 steel) after grinding with an Al2O3 grinding wheel with the cutting fluid delivered via flood technique at different temperatures: 5 °C, 10 °C, 15 °C as well as room temperature (28 ± 1 °C). The surface integrity of the workpiece was analyzed in terms of surface roughness (Ra parameter), images of the ground surface, and the microhardness and microstructure beneath the machined surface. The results show that the surface roughness values reduced with the cutting fluid temperature. Furthermore, the application of a cutting fluid at low temperatures enabled the minimization of thermal damages regarding visible grinding burns, hardness variation, and microstructure changes. Full article
(This article belongs to the Special Issue Modelling and Simulation in Metal Cutting and Machining Process)
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Review

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35 pages, 30824 KiB  
Review
Influence of Honing Parameters on the Quality of the Machined Parts and Innovations in Honing Processes
by Piotr Sender and Irene Buj-Corral
Metals 2023, 13(1), 140; https://doi.org/10.3390/met13010140 - 10 Jan 2023
Cited by 2 | Viewed by 2769
Abstract
The article presents a literature review dealing with the effect of the honing parameters on the quality of the machined parts, as well as with the recent innovations in honing processes. First, an overview about the honing and the plateau-honing processes is presented, [...] Read more.
The article presents a literature review dealing with the effect of the honing parameters on the quality of the machined parts, as well as with the recent innovations in honing processes. First, an overview about the honing and the plateau-honing processes is presented, considering the main parameters that can be varied during machining. Then, the influence of the honing parameters on surface finish, shape deviation and material removal rate is presented. Finally, some special and innovative applications of the honing process are described. For example, honing with variable kinematics allows obtaining oil grooves that are not rectilinear but curvilinear, in order to reduce the temperature of the part during machining and thus achieving better surface finish and lower shape deviation. Automation of the honing machines is useful to improve both the production and the verification process. Another innovation consists of using 3D printed tools in honing processes, which will help to obtain abrasive tools with complex shapes, for example by means of powder bed fusion processes. Full article
(This article belongs to the Special Issue Modelling and Simulation in Metal Cutting and Machining Process)
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