Search for Articles:
Title / Keyword
Author / Affiliation / Email
Journal
Article Type
 
 
Advanced Search
 
Section
Special Issue
Volume
Issue
Number
Page
 
4.4
2.9
Journals
Metals
Special Issues
High Performance Machining of Difficult-to-Process Metals
share announcement

High Performance Machining of Difficult-to-Process Metals

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: 15 September 2024 | Viewed by 6236

Special Issue Editors

Prof. Dr. Zhanqiang Liu

E-Mail Website
Guest Editor
School of Mechanical Engineering, Shandong University, Jinan 250061, China
Interests: structural vibration control; machining theory; tool technology
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Qinghua Song

E-Mail Website
Guest Editor
School of Mechanical Engineering, Shandong University, Jinan 250061, China
Interests: high-performance manufacturing; intelligent monitoring for machining process; structural vibration and control; biomedical machinery
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Bing Wang

E-Mail Website
Guest Editor
School of Mechanical Engineering, Shandong University, Jinan 250061, China
Interests: metal cutting and cutting tools; high-speed machining; machined surface integrity; material dynamic properties
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Yukui Cai

E-Mail Website
Guest Editor
School of Mechanical Engineering, Shandong University, Jinan 250061, China
Interests: laser machining; micro- and precision machining; fluid dynamics simulation

Special Issue Information

Dear Colleagues,

Mechanical machining or cutting, as a subtractive manufacturing operation, is one of the most widely used manufacturing processes. High-performance machining has attracted more and more attention in recent years as it can evaluate the machining process comprehensively. In particular, for the functional machined surfaces of mechanical components, such as load-carrying and frictional surfaces, the machining process has crucial effects on the service performance of the components themselves and even entire working systems. Extensive research involving experiments, analytical modeling, and numerical simulation of the machining process has been conducted to understand the interaction between cutting tools and workpiece materials. The research outcomes can promote steady progress of the machining performance through the optimization of process planning and advancement of cutting tools and machining equipment.

With the rapid development of advanced engineering materials, such as high-strength alloys and ceramic matrix composites, these have caused new challenges in the field of machining due to their difficult-to-process attributes. In addition, the working conditions of machined surfaces are becoming more extreme, due to higher stress and strain, higher temperatures, more severe altering loadings, and more corrosive environments. To reveal the relationships among “workpiece material property-machining process-machined surface integrity-component functionality” it is important to achieve high production rates and the demanded surface quality, which can then lay a foundation to promote machining performance.

The scope of this Special Issue embraces original research and review articles in the field of high-performance machining of difficult-to-process materials. Manuscripts will be welcomed that aim to understand the machinability of different materials, modelling and simulation of material removal behavior, exploring the machined surface integrity and functionality, advancing the machining process and cutting tools, and mapping the relationships of “material property-machining process-surface quality and performance”.

Prof. Dr. Zhanqiang Liu
Prof. Dr. Qinghua Song
Prof. Dr. Bing Wang
Prof. Dr. Yukui Cai
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

  • high-performance machining
  • difficult-to-process materials
  • machinability
  • surface integrity
  • cutting tools
  • hybrid machining
  • functional surface
  • alloys
  • metallurgy

Published Papers (4 papers)

Download All Papers
Order results
Result details
Show export options expand_more Show export options expand_less
Select all
Export citation of selected articles as:

Research

15 pages, 5072 KiB  
Article
Simulation of Mechanical Response in Machining of Ti-6Al-4V Based on Finite Element Model and Visco-Plastic Self-Consistent Model
by Qingqing Wang, Chengli Yang, Haifeng Yang and Yibo He
Metals 2023, 13(8), 1362; https://doi.org/10.3390/met13081362 - 28 Jul 2023
Viewed by 912
Abstract
The predictions of mechanical responses (stress–strain variations) in the machining of Ti-6Al-4V alloy are important to analyze the deformation conditions of machining to optimize the machining parameters and investigate the generation of a machined surface. The selection of a constitutive model is an [...] Read more.
The predictions of mechanical responses (stress–strain variations) in the machining of Ti-6Al-4V alloy are important to analyze the deformation conditions of machining to optimize the machining parameters and investigate the generation of a machined surface. The selection of a constitutive model is an essential factor that determines the deformation behavior in the machining simulation model. In this paper, two constitutive models of a modified Johnson–Cook (JC) equation and visco-plastic self-consistent (VPSC) model were used to investigate the stress–strain evolutions in the machining process of Ti-6Al-4V. A finite element (FE) machining model was established, considering the influences of grain refinement and deformation twins, based on a modified JC equation. The VPSC model was fitted based on the macro-strain rate sensitivity of the JC equation. The prediction results of the stress–strain curves of two models were compared, and their validities were further proved. The results show that flow stress hardening and inhomogeneities are caused by multi-scale grain refinement during the machining process of Ti-6Al-4V. Five slip deformation modes and one compressive twinning mode were activated in the VPSC model to be consistent with the macro-deformation behavior predicted with the FE model. The validations show the effectiveness of the modified JC equation, considering microstructural changes and the fitted VPSC model, in predicting dynamic behavior in the machining process of Ti-6Al-4V. The results provide two aspects of macro-deformation and polycrystal plasticity to elucidate the stress variations that occur during the machining of Ti-6Al-4V. Full article
(This article belongs to the Special Issue High Performance Machining of Difficult-to-Process Metals)
►▼ Show Figures

Figure 1

39 pages, 13659 KiB  
Article
Prediction of Tool Wear Rate and Tool Wear during Dry Orthogonal Cutting of Inconel 718
by Ziqi Zhang, Zhanqiang Liu, Xiaoping Ren and Jinfu Zhao
Metals 2023, 13(7), 1225; https://doi.org/10.3390/met13071225 - 3 Jul 2023
Cited by 4 | Viewed by 1606
Abstract
A new prediction method was proposed based on the positive feedback relationship between tool geometry and tool wear rate. Dry orthogonal cutting of Inconel 718 was used as a case study. Firstly, tool wear rate models and a tool wear prediction flowchart were [...] Read more.
A new prediction method was proposed based on the positive feedback relationship between tool geometry and tool wear rate. Dry orthogonal cutting of Inconel 718 was used as a case study. Firstly, tool wear rate models and a tool wear prediction flowchart were proposed. Secondly, the evolution of the tool geometry during tool wear was analyzed considering the combined effect of tool crater wear and tool flank wear. Thirdly, the evolution of the cutting temperature, normal stress and tool–chip relative sliding velocity on the tool wear surface was studied, the evolution of the tool wear rate during tool wear was revealed. Finally, the evolution of the tool geometry and tool wear rate during tool wear were applied to the tool wear prediction method to accurately predict the tool wear. The prediction error of KT is less than 15% in comparison with the experimental results. The tool wear prediction method in this paper is helpful to improve the prediction accuracy of tool crater wear. Full article
(This article belongs to the Special Issue High Performance Machining of Difficult-to-Process Metals)
►▼ Show Figures

Graphical abstract

14 pages, 21086 KiB  
Article
Cutting Chatter in Ultrasonic Elliptical Vibration Cutting and Its Influence on Surface Roughness and Tool Wear
by Gan Li, Jinbo Liu, Yanan Pan, Yan Bao, Sen Yin, Zhigang Dong and Renke Kang
Metals 2023, 13(6), 1078; https://doi.org/10.3390/met13061078 - 7 Jun 2023
Cited by 3 | Viewed by 1340
Abstract
Ultrasonic elliptical vibration cutting has a wide range of applications in the field of precision cutting of difficult-to-machine metal materials. However, due to its intermittent cutting characteristics and the weak rigidity of the horn, cutting chatter is prone to occur during its cutting [...] Read more.
Ultrasonic elliptical vibration cutting has a wide range of applications in the field of precision cutting of difficult-to-machine metal materials. However, due to its intermittent cutting characteristics and the weak rigidity of the horn, cutting chatter is prone to occur during its cutting process, which has an important impact on cutting surface quality and tool wear. In this paper, the rigid/viscoplastic rod model is used to simulate the horn in the ultrasonic elliptical vibration cutting device, and the influence factors of the amplitude-frequency response of the horn are analyzed. The influence of cutting speed and cutting depth on cutting chatter was studied by ultrasonic elliptical vibration cutting experiment of tungsten heavy alloy, and the influence of cutting chatter on cutting surface morphology and diamond tool wear was studied. The research shows that cutting speed will change the excitation frequency of the horn, and reasonable cutting speed can inhibit the occurrence of cutting chatter and avoid resonance of the horn. The cutting depth will affect the excitation amplitude and amplify the vibration amplitude when chatter or resonance occurs. The experimental results show that in ultrasonic elliptical vibration cutting of heavy tungsten alloy, chatter suppression can significantly improve the quality of the cutting surface and reduce the wear of diamond tools. Full article
(This article belongs to the Special Issue High Performance Machining of Difficult-to-Process Metals)
►▼ Show Figures

Figure 1

20 pages, 12131 KiB  
Article
Dynamic Modeling and Stability Prediction of Robot Milling Considering the Influence of Force-Induced Deformation on Regenerative Effect and Process Damping
by Yuchao Du, Zhiqiang Liang, Sichen Chen, Hao Huang, Haoran Zheng, Zirui Gao, Tianfeng Zhou, Zhibing Liu and Xibin Wang
Metals 2023, 13(5), 974; https://doi.org/10.3390/met13050974 - 18 May 2023
Cited by 1 | Viewed by 1398
Abstract
Undesirable chatter is one of the key problems that restrict the improvement of robot milling quality and efficiency. The prediction of chatter stability, which is used to guide the selection of process parameters, is an effective method to avoid chatter in robot milling. [...] Read more.
Undesirable chatter is one of the key problems that restrict the improvement of robot milling quality and efficiency. The prediction of chatter stability, which is used to guide the selection of process parameters, is an effective method to avoid chatter in robot milling. Due to the weak stiffness of the robot, deformation caused by milling forces becomes an unavoidable problem, which will change the tool–workpiece contact area and affect the stability prediction. However, it is often simplified and neglected. In this paper, a multipoint contact dynamic model of robot milling is established, which considers the influence of force-induced deformation on the regenerative effect and process damping. The tool–workpiece contact area is discretized into a finite number of nodes along the axial direction so that the force and deformation at each node can be calculated separately. The different contact forms of the tool–workpiece under different process parameters are discussed in different cases, and the interaction process between cutting force and force-induced deformation is analyzed in detail. An iterative strategy is used to calculate the deformation of each node and the result of the tool–workpiece contact boundary. Finally, chatter stability of robot milling is predicted by a fully discrete method. Robot milling experiments were carried out to verify the predicted results. The results show that force-induced deformation is an important factor improving the stability prediction accuracy of robot milling, and a more accurate prediction result can be obtained by simultaneously considering force-induced deformation and process damping. Full article
(This article belongs to the Special Issue High Performance Machining of Difficult-to-Process Metals)
►▼ Show Figures

Figure 1

Show export options expand_more Show export options expand_less
Select all
Export citation of selected articles as:
 
Displaying articles 1-4
Back to TopTop