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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (31 December 2022) | Viewed by 14680

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Special Issue Editors

Dr. Zhiqiang Liang

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Guest Editor

School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China
Interests: precision and ultra-precision grinding; cutting of difficult-to-cut materials; design and fabrication of micro-tools and machine tools
Special Issues, Collections and Topics in MDPI journals

Dr. Lijing Xie

E-Mail Website
Guest Editor

Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology, Beijing 100081, China
Interests: high speed cutting; high performance cutting; multiscale modeling and prediction

Special Issue Information

Dear Colleagues,

With the development of high-end equipment, difficult-to-cut materials with high strength and high hardness increasingly play an important role in the production of high load-bearing structural components. Additionally, the requirement for higher geometrical precision, better physical properties and a longer component service life has substantially increased. With that, the manufacturing industry faces the challenges of coordinating the geometrical state of machined surfaces with their physical and mechanical states, and, simultaneously, the difficulties of balancing machining quality and efficiency. Motivated by these challenges and difficulties, an increasing number of new cutting technologies are being developed. Due to the multidisciplinary characteristic of the machining process, the development of cutting technologies is enabled and accompanied by achievements in the domains of workpiece materials, tool materials, machine tools, processing conditions, fatigue and environments. In the end, these domains contribute to the improvement in the reliability and service performance of high-end equipment. This Special Issue is focused on the development and applications of new metal cutting technologies and tools.

Articles concerning difficult-to-cut materials and their machining, testing, multiscale modeling and prediction are welcomed. This is an excellent opportunity for metal cutting scientists and engineers all over the world to share their latest achievements. This Special Issue will cover, but is not limited to, the following fundamental and applied research topics:

Difficult-to-machine materials;
High-strength steels;
Stainless steels;
Superalloys;
Titanium alloys;
High-speed cutting;
High-performance cutting;
Hard machining;
Dry machining;
Ultrasonic-assisted cutting;
Nano/micro/meso-cutting;
Turning;
Milling;
Drilling;
Grinding;
Microtools;
Advanced cutting tools;
Cutting tool design;
Cutting tool manufacture;
Cutting fluids;
Cutting simulation;
Cutting dynamics;
Surface integrity;
Non-destructive testing;
Multiscale modeling and prediction.

Dr. Zhiqiang Liang
Dr. Lijing Xie
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

difficult-to-machine materials
high-strength steels
stainless steels
superalloys
titanium alloys
high-speed cutting
high-performance cutting
hard machining
dry machining
ultrasonic-assisted cutting
nano/micro/meso-cutting
turning
milling
drilling
grinding
microtools
advanced cutting tools
cutting tool design
cutting tool manufacture
cutting fluids
cutting simulation
cutting dynamics
surface integrity
non-destructive testing
multiscale modeling and prediction

Published Papers (10 papers)

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Research

11 pages, 1685 KiB

Open AccessArticle

Effect of Different Heat Treatments and Surface Treatments on the Mechanical Properties of Nickel-Titanium Rotary Files

by Jihye Hong, Sang Won Kwak, Jung-Hong Ha, Asgeir Sigurdsson, Ya Shen and Hyeon-Cheol Kim

Metals 2023, 13(10), 1769; https://doi.org/10.3390/met13101769 - 18 Oct 2023

Viewed by 986

Abstract

This study aimed to compare the fatigue resistance of files made from different heat treatment methods and surface treatment. Four prototype files were created through heat treatment and titanium coating surface treatment (AT, DT, ER, EN; named arbitrarily by the manufacturer) at different times and temperatures. Artificial canals with curvatures of 45- and 90-degree were used for the fatigue testing. The files were operated at the speed of 500 rpm at 37 °C, and the time until fracture incurred by a 4-mm dynamic pecking motion at a speed of 8 mm/s was measured, and the number of cycles to failure (NCF) was calculated by applying rotation speed and time. The length of the fractured fragment was measured. The fractured specimens were observed under the SEM to compare the characteristics of fatigue fracture patterns. Differential scanning calorimetry analysis was performed to estimate the phase transformation temperature. One-way ANOVA with Duncan’s post-hoc comparison, the Kruskal–Wallis test, and Mann–Whitney U were applied to compare the fatigue resistance among the prototypes at a significance level of 95%. Regardless of the canal angle, the EN showed the highest fatigue resistance (p < 0.05). AT had the lowest NCF at the 90-degree canal (p < 0.05). ER had a higher NCF than the DT at 45 degrees (p < 0.05), but there was no difference at 90 degrees. DSC analysis revealed that the ER and EN groups exhibited two austenite peaks above 40 °C. In conclusion, the file that underwent a specific temperature heat treatment with titanium coating surface treatment showed the highest fatigue resistance. Full article

(This article belongs to the Special Issue Advanced Metal Cutting Technology and Tools)

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14 pages, 14723 KiB

Open AccessArticle

Development of a New Micro Drilling Tool with H-Shaped Chisel Edge

by Yue Ma, Zhiqiang Liang, Kun Wan, Rongbin Cai, Linfeng Yi, Jianfei Li, Fei Wang, Xu Zhao, Rui Chen and Xibin Wang

Metals 2023, 13(3), 608; https://doi.org/10.3390/met13030608 - 17 Mar 2023

Cited by 2 | Viewed by 1245

Abstract

In order to improve the tool life and micro-hole machining quality, the H-shaped chisel edge micro-drill (HCE-MD) was developed in this paper. The HCE-MD was characterized by the inner edge formed through the chisel edge thinning. In the micro-drilling process, the inner edge can perform positive rake cutting, so the machining area of the workpiece extruded by cutting edge with a negative rake angle is reduced. Based on this, the distribution of rake angle near the chisel edge corner is improved. Then, the HCE-MD was fabricated on the six-axis CNC grinding machine. The grinding process parameters of the micro-drill were optimized based on the orthogonal grinding test and grey relational grade theory. The size and shape accuracy of the micro-drill were controlled by the multi-axis linkage grinding method and the movement-axis micro compensation method. Finally, the 0.25 mm HCE-MD was fabricated with the cutting edge radius of 1.94 μm and the flank surface roughness of 0.25 μm. The drilling performance of HCE-MD was evaluated through comparative drilling experiments. The experimental results show that, compared with common micro drill, the HCE-MD produced lower thrust force and better micro-hole roundness accuracy, and reduced the micro-drill wear on the chisel edge and the flank. Full article

(This article belongs to the Special Issue Advanced Metal Cutting Technology and Tools)

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13 pages, 5160 KiB

Open AccessArticle

Study of the Machinability of an Inconel 625 Composite with Added NiTi-TiB₂ Fabricated by Direct Laser Deposition

by Alexey Arlyapov, Sergey Volkov, Vladimir Promakhov, Alekey Matveev, Artem Babaev, Alexander Vorozhtsov and Alexander Zhukov

Metals 2022, 12(11), 1956; https://doi.org/10.3390/met12111956 - 15 Nov 2022

Cited by 4 | Viewed by 1186

Abstract

This work studies the process feasibility of milling a metal-matrix composite based on Inconel 625 with added NiTi-TiB₂ fabricated by direct laser deposition. The composite is intended for manufacturing turbine blades and it has strength characteristics on par with those of Inconel 625. However, the addition of TiB₂ has improved its heat and wear resistance. This material is new, and its machinability has not been studied. The new composite was milled with end mill cutters, and recommendations were worked out on the cutting speed, feed per tooth, cutter flank angle, as well as depth and width of milling. The wear of cutter teeth flank was more intense. After the flank wear land on the back surface of a tooth had reached 0.11–0.15 mm, there was a sharp increase in the forces applied which was followed by brittle fracture of the tooth. Milling at a speed of 25 m/min ensured 28 min of stable operation. However, afterwards the critical wear value of 0.11 mm was quickly approached at a cutting speed of 50 m/min, and critical wear followed after 14 min. Dependencies of the cutting forces vs. time for all the selected cutting speeds and throughout the entire testing time period have a tendency to increase, which indicates the influence of cutter wear on the cutting forces. It was found that the durability of the cutters increases with an increase in the milling width and a decrease in the milling depth. Full article

(This article belongs to the Special Issue Advanced Metal Cutting Technology and Tools)

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17 pages, 10007 KiB

Open AccessArticle

Simulation Analysis and Experimental Study on SLM Forming Titanium Alloy Milling Hole

by Wentian Shi, Tianming Yan, Yude Liu, Xiaoqing Zhang, Jihang Li, Lin Wang and Lu Dong

Metals 2022, 12(11), 1919; https://doi.org/10.3390/met12111919 - 09 Nov 2022

Cited by 6 | Viewed by 1506

Abstract

Using finite element analysis software and based on the Johnson–Cook failure criterion, a 3D printing workspace model with collapse, powder sticking, and cavity defects was established under the selective laser melting (SLM) forming process. The simulation analysis of milling holes was carried out, and the relationship between cutting speed and material-removal rate on tool wear and entrance burr was derived. The hole-milling experiment was carried out to verify the dimensional accuracy and surface appearance of the hole under the two processes of SLM direct forming and re-milling after forming; the inhibition effect of re-milling after forming on collapse, powder sticking, and cavity defects in hole forming were studied, and the formation mechanism of various defects such as burrs, scratches, and hole-wall cracks in the hole-milling process was analyzed. The Kistler9129A dynamometer was used to measure the cutting forces of re-milling holes and direct milling holes, and a comparative analysis was carried out. The influence of cutting speed, hole diameter, and material-removal rate on the axial force of milling holes was explored. The experiment results were consistent with the simulation cutting model, and the model’s accuracy was verified. Full article

(This article belongs to the Special Issue Advanced Metal Cutting Technology and Tools)

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13 pages, 12359 KiB

Open AccessArticle

Experimental Investigation of Thrust Force in the Drilling of Titanium Alloy Using Different Machining Techniques

by Lijie Ma, Zunyan Ma, Hui Yu, Shenwang Li, Minghua Pang and Zhankui Wang

Metals 2022, 12(11), 1905; https://doi.org/10.3390/met12111905 - 07 Nov 2022

Cited by 2 | Viewed by 1208

Abstract

Titanium alloy is a kind of hard-to-cut material widely used in aerospace, military and medical fields, and mechanical drilling is the primary technique used for hole-making in titanium alloy materials. The drilling force is an inevitable concomitant phenomenon in the drilling process and thrust force is its most important component. During the drilling of titanium alloy, it is crucial to understand the fundamental characteristics and changing rules of thrust force for optimizing process parameters, improving machining quality and predicting tool failure. In this paper, four different techniques, such as direct drilling (DD), ultrasonic vibration drilling (UVD), peck drilling (PD) and ultrasonic vibration peck drilling (UVPD), were used to drill small holes into Ti-6Al-4V titanium alloy, the thrust force was measured and its mean, maximum and peak-to-valley value were acquired from the time-domain waveform. Then the time-domain and frequency-domain characteristics of thrust force under the four techniques were compared, and the changing rules of thrust force with vibration amplitudes during UVD and UVPD were investigated. The results showed that, when compared to DD, UVD decreased the mean thrust force F_a_mean by about 18.6%, and the force reduction effect was more significant as the amplitude increased. The variable velocity cutting characteristics and the antifriction effect of UVD were the primary reasons for the reduction of F_a_mean. The pecking motion and ultrasonic vibration had a synergistic effect on reducing thrust force; UVPD could simultaneously reduce the mean thrust force F_a_mean and maximum thrust force F_a_max. When the amplitude A was chosen within the range of 2–3 μm, F_a_max and F_a_mean were reduced by approximately 37% and 40% in comparison to DD. Full article

(This article belongs to the Special Issue Advanced Metal Cutting Technology and Tools)

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16 pages, 4633 KiB

Open AccessArticle

Multialgorithm Fusion for Milling Tool Abrasion and Breakage Evaluation Based on Machine Vision

by Chao Wu, Yixi Hu, Tao Wang, Yeping Peng, Shucong Qin and Xianbo Luo

Metals 2022, 12(11), 1825; https://doi.org/10.3390/met12111825 - 27 Oct 2022

Cited by 1 | Viewed by 1175

Abstract

Aiming at the problem that the current tool status monitoring system cannot measure the area of the abrasion and breakage from the milling tool images at the same time, a new detection fusion method for milling tool abrasion and breakage based on machine vision is proposed. This method divides the milling tool status into abrasion and breakage. The abrasion is recognized by an adaptive region localization growing method, and the breakage is recognized by an edge fitting reconstruction method based on distance threshold. Then, the area of tool damage can be accurately measured based on the identified abrasion and breakage information. Experiments show that the proposed method could effectively detect both the tool abrasion and breakage, and provide a better monitoring effect than that of the conventional method that only considers tool abrasion status. The proposed approach was verified by the experimental results, and the accuracy of the tool damage area characteristic was over 95%. Full article

(This article belongs to the Special Issue Advanced Metal Cutting Technology and Tools)

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8 pages, 4394 KiB

Open AccessArticle

Pulsed Magnetic Treatment of Cobalt for Enhanced Microstructures and Mechanical Properties

by Yajie Li, Han Guo, Lin Zhang, Zhe Chen, Lanhui Liu and Jian Liu

Metals 2022, 12(11), 1775; https://doi.org/10.3390/met12111775 - 22 Oct 2022

Cited by 1 | Viewed by 1314

Abstract

In this study, the effects of pulsed magnetic treatment (PMT) on the microstructure and performance of pure bulk cobalt (Co) were investigated to reveal the underlying influencing mechanism of the pulsed magnetic field on ferromagnetic materials. The hardness of the material could be increased by PMT, with a maximum increase of 3.16% when 1T was adopted. The imposition of the pulsed field promoted the transformation of Co from face-centered cubic (FCC) phase to hexagonal close-packed (HCP) phase, which obeys the Shoji–Nishiyama orientation rule, with a decrease of α-Co by 8.60% and an increase of ε-Co by 0.19%. PMT also caused multiplication of defects and the formation of low-angle grain boundaries within the bulk Co. PMT could be an effective way to modify materials to suit engineering applications. Full article

(This article belongs to the Special Issue Advanced Metal Cutting Technology and Tools)

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13 pages, 8790 KiB

Open AccessArticle

Simulation Study of Ultrasonic Elliptical Vibration Cutting of TiC Particle-Reinforced Titanium Matrix Composites

by Haixiang Huan, Wenqiang Xu, Biao Zhao, Ke Zhang, Jianfei Pu and Chilei Zhu

Metals 2022, 12(10), 1769; https://doi.org/10.3390/met12101769 - 21 Oct 2022

Cited by 6 | Viewed by 1280

Abstract

In order to investigate the characteristics of elliptical ultrasonic vibration cutting of TiC particle-reinforced titanium matrix composites, a two-dimensional thermodynamic coupled finite element cutting model was established based on the Johnson-Cook intrinsic structure model using ABAQUS simulation software, and the changes in cutting force, cutting temperature, machined surface shape, and particle fragmentation were obtained under the traditional cutting method and ultrasonic elliptical vibration cutting method. The results show that under the same process parameters, ultrasonic elliptical vibration cutting is better than conventional cutting in terms of surface profile; the stress direction tends to be horizontal during cutting and the TiC particles are mainly removed by cutting off. The average cutting force is significantly lower than conventional cutting, with a maximum reduction of 60%. The cutting temperature is also reduced, with a reduction of approximately 17.6%. Full article

(This article belongs to the Special Issue Advanced Metal Cutting Technology and Tools)

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8 pages, 2158 KiB

Open AccessArticle

An Experimental Study of the Surface Roughness of SiCp/Al with Ultrasonic Vibration-Assisted Grinding

by Jie Ying, Zhen Yin, Peng Zhang, Peixiang Zhou, Kun Zhang and Zihao Liu

Metals 2022, 12(10), 1730; https://doi.org/10.3390/met12101730 - 16 Oct 2022

Cited by 5 | Viewed by 1232

Abstract

Due to the differences in mechanical properties of Al and SiC particles, the problems of SiC particle pullout and high surface roughness will occur in the processing of SiCp/Al composites. However, the ultrasonic vibration-assisted grinding of SiCp/Al can effectively decrease the appearance of such problems. A comparative experimental study of the ultrasonic vibration-assisted and ordinary grinding of SiCp/Al is conducted. First, the effect of ultrasonic amplitude on the removal form of SiC is summarized by observing the surface morphology of the sample. Then, the primary reasons for the pullout of SiC particles and high surface roughness in SiCp/Al processing are analyzed. The variation law of the surface roughness of SiCp/Al under different ultrasonic amplitudes and grinding parameters is summarized through a single-factor experiment. The results show that ultrasonic vibration-assisted grinding is beneficial for reducing the surface roughness of SiCp/Al. When grinding linear speed of grinding wheel v_s increases from 2.512 m/s to 7.536 m/s, surface roughness R_a decreases from 0.25 µm to 0.16 µm. when feed rate v_w increases from 100 mm/min to 1700 mm/min, surface roughness R_a increases from 0.13 µm to 0.20 µm. When grinding depth a_p increases from 0.01 mm to 0.05 mm, surface roughness R_a increases from 0.13 µm to 0.19 µm. When ultrasonic amplitude A is increased from 0 µm to 2 µm, surface roughness R_a decreases from 0.26 µm to 0.15 µm. When ultrasonic amplitude A is increased from 2 µm to 4.4 µm, surface roughness R_a increases from 0.15 µm to 0.18 µm. Full article

(This article belongs to the Special Issue Advanced Metal Cutting Technology and Tools)

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12 pages, 6742 KiB

Open AccessArticle

Machining Distortion for Thin-Walled Superalloy GH4169 Caused by Residual Stress and Manufacturing Sequences

by Pingzhong Zhu, Zhanqiang Liu, Xiaoping Ren and Yukui Cai

Metals 2022, 12(9), 1460; https://doi.org/10.3390/met12091460 - 31 Aug 2022

Cited by 3 | Viewed by 1428

Abstract

The residual stress generated in the machining process has a passive influence on the machining accuracy of a thin-walled workpiece. Annealing treatment can release the residual stress induced in the machining process and suppress the machining distortion. However, there is no unified standard for whether annealing treatment is arranged after machining. In this paper, an analytical model for predicting the distortion caused by residual stress of thin-walled superalloy GH4169 is established. Then, the finite element method is applied to analyze the prediction results of the proposed model. It is found that the residual stress generated in the manufacturing process chain can cause large distortion for the thin-walled workpiece. Finally, combined with the law and principle of workpiece distortion, the annealing process planning of multiple manufacturing sequences of thin-walled superalloy GH4169 is formulated to suppress the machining distortion. For the machining process on one side of the workpiece, it is necessary to release residual stress. This is not necessary for the double-sided machining process. Research results can be used to optimize the manufacturing sequence of thin-walled components. Full article

(This article belongs to the Special Issue Advanced Metal Cutting Technology and Tools)

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