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Micromachines
Special Issues
High-Quality Surface Integrity of Ultra-Precision Machining
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High-Quality Surface Integrity of Ultra-Precision Machining

A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "D：Materials and Processing".

Deadline for manuscript submissions: 15 June 2024 | Viewed by 4580

Special Issue Editors

Dr. Xiaoliang Liang

E-Mail Website
Guest Editor
Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong 999077, China
Interests: metal cutting and cutting tools; machined surface integrity; ultra-precision machining
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Yanbin Zhang

E-Mail Website
Guest Editor
School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China
Interests: intelligent manufacturing; sustainable manufacturing; precision machining
Special Issues, Collections and Topics in MDPI journals
Dr. Kangsen Li

E-Mail Website
Guest Editor
Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong 999077, China
Interests: functional surfaces; precision glass molding; hot embossing; advanced manufacturing; optical design
Dr. Huapan Xiao

E-Mail Website
Guest Editor
Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong 999077, China
Interests: wire sawing; grinding; polishing; diamond turning; ultra-precision machining; precision metrology
Special Issues, Collections and Topics in MDPI journals
Dr. Changlin Liu

E-Mail Website
Guest Editor
Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong 999077, China
Interests: ultra-precision machining; nanoscale material removal mechanism; molecular dynamics simulation; laser-assisted machining

Special Issue Information

Dear Colleagues,

Machining is a complex dynamic process involving nonlinear and diverse coupling phenomena, such as thermo-mechanical coupled stress, large elastic–plastic deformation, tribological conditions, and chip separation. Surface integrity is a technical index used to describe, identify, and control the possible changes in the machined surface layer and affect the functional performance of manufacturing components. The surface integrity of machining parts ensures that the surface layer of the part is intact after machining, which indicates that the metallographic structure of the machined surface layer, as well as their mechanical and physical properties, can meet the application requirements of use, and guarantee that the manufacturing components have a certain service life. With the development of modern manufacturing technology, the surface quality requirements of manufacturing products are becoming more and more stringent. In order to make ultra-precision machining and surface finishing adapt to the new situation, scholars have conducted more in-depth research on the machined surface integrity, and proposed an objective, scientific, and systematic surface integrity evaluation system. This Special Issue aims to publish original research and review articles in the field of "High-quality surface integrity in Ultra-precision Machining". Papers on new theories, techniques, and applications in the fields of precision engineering, microengineering, and nanotechnology are welcome. We also welcome scholars in related fields to contribute their latest research results to this special issue.

Suitable topics include, but are not limited to, the following.

  • Complex surface measurement and evaluation characterization;
  • Subsurface damage and defect detection;
  • Metrology and ultra-precision surface integrity evaluation;
  • Advanced manufacturing technologies, such as turning/milling/grinding/polishing/hybrid processing;
  • Nano/microfabrication technologies;
  • Assisted machining technologies;
  • Laser processing and surface treatment;
  • Cooling/lubrication and green manufacturing technologies;
  • Ultra-precision system integration and equipment development;
  • Optimal design of the entire process chain for ultra-precision machining;
  • System design and simulation;
  • Machining mechanics, applications, and challenges, etc.

Dr. Xiaoliang Liang
Prof. Dr. Yanbin Zhang
Dr. Kangsen Li
Dr. Huapan Xiao
Dr. Changlin Liu
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. Micromachines 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

  • surface integrity evaluation
  • material removal mechanism
  • ultra-precision machining
  • advanced manufacturing

Published Papers (4 papers)

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Research

20 pages, 5296 KiB  
Article
Understanding Melt Pool Behavior of 316L Stainless Steel in Laser Powder Bed Fusion Additive Manufacturing
by Zilong Zhang, Tianyu Zhang, Can Sun, Sivaji Karna and Lang Yuan
Micromachines 2024, 15(2), 170; https://doi.org/10.3390/mi15020170 - 23 Jan 2024
Cited by 1 | Viewed by 1306
Abstract
In the laser powder bed fusion additive manufacturing process, the quality of fabrications is intricately tied to the laser–matter interaction, specifically the formation of the melt pool. This study experimentally examined the intricacies of melt pool characteristics and surface topography across diverse laser [...] Read more.
In the laser powder bed fusion additive manufacturing process, the quality of fabrications is intricately tied to the laser–matter interaction, specifically the formation of the melt pool. This study experimentally examined the intricacies of melt pool characteristics and surface topography across diverse laser powers and speeds via single-track laser scanning on a bare plate and powder bed for 316L stainless steel. The results reveal that the presence of a powder layer amplifies melt pool instability and worsens irregularities due to increased laser absorption and the introduction of uneven mass from the powder. To provide a comprehensive understanding of melt pool dynamics, a high-fidelity computational model encompassing fluid dynamics, heat transfer, vaporization, and solidification was developed. It was validated against the measured melt pool dimensions and morphology, effectively predicting conduction and keyholing modes with irregular surface features. Particularly, the model explained the forming mechanisms of a defective morphology, termed swell-undercut, at high power and speed conditions, detailing the roles of recoil pressure and liquid refilling. As an application, multiple-track simulations replicate the surface features on cubic samples under two distinct process conditions, showcasing the potential of the laser–matter interaction model for process optimization. Full article
(This article belongs to the Special Issue High-Quality Surface Integrity of Ultra-Precision Machining)
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12 pages, 11987 KiB  
Article
Fabrication of Dimples by Jet-ECM of Zr-Based Bulk Metallic Glasses with NaCl-Ethylene Glycol Electrolyte
by Cheng Guo, Jingwen He, Weizhen Zhuang, Kangsen Li and Duo Li
Micromachines 2023, 14(12), 2196; https://doi.org/10.3390/mi14122196 - 30 Nov 2023
Cited by 1 | Viewed by 727
Abstract
Zr-based bulk metallic glasses (BMGs) possess unique mechanical and biochemical properties, which have been widely noticed. Jet electrochemical machining (jet-ECM), characterized by a high-speed jet, is a non-contact subtractive method with a high resolution and a high material removal rate (MRR). Past work [...] Read more.
Zr-based bulk metallic glasses (BMGs) possess unique mechanical and biochemical properties, which have been widely noticed. Jet electrochemical machining (jet-ECM), characterized by a high-speed jet, is a non-contact subtractive method with a high resolution and a high material removal rate (MRR). Past work on the electropolishing of Zr-based BMGs has indicated the feasibility of the NaCl-Ethylene Glycol (EG) electrolyte. In this research, the jet-ECM of Zr-based BMGs in the NaCl-EG electrolyte was studied to explore the dissolving mechanisms and surface integrity according to the voltage, pulse-on time and effective voltage time. The diameter, depth and surface morphologies of dimples were evaluated. The results showed that using this alcohol-based electrolyte led to a desirable surface morphology. The diameter and depth of the dimples varied with the voltage and the effective voltage time in a significantly positive proportional manner. Additionally, cases based on multiple parameter sets exhibited different stray corrosion severity. Afterward, machining performance can be enhanced in the next stage by tuning machining parameters to obtain microscale dimples with better quality. Full article
(This article belongs to the Special Issue High-Quality Surface Integrity of Ultra-Precision Machining)
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12 pages, 12130 KiB  
Article
Research on the Preparation and Application of Fixed-Abrasive Tools Based on Solid-Phase Reactions for Sapphire Wafer Lapping and Polishing
by Linlin Cao, Xiaolong Zhou, Yingjie Wang, Zhilun Yang, Duowen Chen, Wei Wei and Kaibao Wang
Micromachines 2023, 14(9), 1797; https://doi.org/10.3390/mi14091797 - 20 Sep 2023
Viewed by 790
Abstract
Single-crystal sapphire specimen (α-Al2O3) have been widely applied in the semiconductor industry, microelectronics, and so on. In order to shorten the production time and improve the processing efficiency of sapphire processing, an integrated fixed-abrasive tool (FAT) based on solid-phase [...] Read more.
Single-crystal sapphire specimen (α-Al2O3) have been widely applied in the semiconductor industry, microelectronics, and so on. In order to shorten the production time and improve the processing efficiency of sapphire processing, an integrated fixed-abrasive tool (FAT) based on solid-phase reactions is proposed in this article. The optimal FAT composition is determined using a preliminary experiment and orthogonal experiments. The mass fraction of the abrasives is chosen as 55 wt%, and the mass ratio of SiO2/Cr2O3 is 2. Surface roughness Ra decreased from 580.4 ± 52.7 nm to 8.1 ± 0.7 nm after 150 min, and the average material removal rate was 14.3 ± 1.2 nm/min using the prepared FAT. Furthermore, FAT processing combined with chemical mechanical polishing (CMP) was shortened by 1.5 h compared to the traditional sapphire production process in obtaining undamaged sapphire surfaces with a roughness of Ra < 0.4 nm, which may have the potential to take the place of the fine lapping and rough polishing process. Full article
(This article belongs to the Special Issue High-Quality Surface Integrity of Ultra-Precision Machining)
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16 pages, 11610 KiB  
Article
Comparison of Surface Morphology and Tool Wear in the Machining of Ti-6Al-4V Alloys with Uncoated and TiAlN Tools under Dry, Minimum Quantity Lubrication, Flood Cooling, and Low-Temperature Spray Jet Cooling Conditions
by Jinfu Zhao, Zhanqiang Liu, Zipeng Gong, Annan Liu, Yukui Cai, Bing Wang, Qinghua Song, Xiaoliang Liang, Yanbin Zhang, Zhicheng Zhang and Haiyang Ji
Micromachines 2023, 14(6), 1263; https://doi.org/10.3390/mi14061263 - 17 Jun 2023
Cited by 2 | Viewed by 1122
Abstract
TiAlN-coated carbide tools have been used to machine Ti-6Al-4V alloys in aviation workshops. However, the effect of TiAlN coating on surface morphology and tool wear in the processing of Ti-6Al-4V alloys under various cooling conditions has not been reported in the public published [...] Read more.
TiAlN-coated carbide tools have been used to machine Ti-6Al-4V alloys in aviation workshops. However, the effect of TiAlN coating on surface morphology and tool wear in the processing of Ti-6Al-4V alloys under various cooling conditions has not been reported in the public published literature. In our current research, turning experiments of Ti-6Al-4V with uncoated and TiAlN tools under dry, MQL, flood cooling, and cryogenic spray jet cooling conditions were carried out. The machined surface roughness and tool life were selected as the two main quantitative indexes for estimating the effects of TiAlN coating on the cutting performance of Ti-6Al-4V under various cooling conditions. The results showed that TiAlN coating makes it hard to improve the machined surface roughness and tool wear of a cutting titanium alloy at a low speed of 75 m/min compared to that achieved by uncoated tools. The TiAlN tools presented excellent tool life in turning Ti-6Al-4V at a high speed of 150 m/min compared to that achieved by uncoated tools. From the perspective of obtaining finished surface roughness and superior tool life in high-speed turning Ti-6Al-4V, the selection of TiAlN tools is feasible and reasonable under the cryogenic spray jet cooling condition. The dedicative results and conclusions of this research could guide the optimized selection of cutting tools in machining Ti-6Al-4V for the aviation industry. Full article
(This article belongs to the Special Issue High-Quality Surface Integrity of Ultra-Precision Machining)
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