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Advances in Precision Machining Technology

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: 20 February 2026 | Viewed by 2777

Special Issue Editors


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Guest Editor
Department of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, 35-959 Rzeszow, Poland
Interests: machining; grinding; cutting tools; grinding wheels; cutting process diagnostics
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Guest Editor
Faculty of Mechanical Engineering, Lodz University of Technology, 90-537 Lodz, Poland
Interests: plunge grinding; machining; diagnostics; signal processing; process optimization; machine dynamics

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Guest Editor
Department of Applied Mechanics, Faculty of Mechanical Engineering, Lublin University of Technology, 20-618 Lublin, Poland
Interests: nonlinear dynamics; time delay; multiple scale method; stability; machining

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Guest Editor
Department of Production Engineering, Mechanical Engineering Faculty, Lublin University of Technology, 20-618 Lublin, Poland
Interests: surface roughness; surface layer properties; brushing; deburring

Special Issue Information

Dear Colleagues,

The machining of modern engineering materials presents an increasing array of challenges. One of the key objectives of mechanical processing is achieving high surface quality as well as precision in shape and dimensional accuracy. This is particularly critical in precision machining. Another essential aspect is efficiency. High-quality outcomes must be coupled with high production efficiency, directly influencing manufacturing costs. A third critical factor is tool durability. Tool wear affects the quality parameters of the manufactured components. Simultaneously, tool life impacts productivity and production costs. Therefore, continuous improvement of precision machining processes is of paramount importance.

This Special Issue is dedicated to advancements in precision machining, particularly focusing on modern and difficult-to-machine materials. The scope of this Special Issue encompasses all aspects related to enhancing machining processes, with an emphasis on optimizing cutting strategies and parameters, innovative tool materials and tool coatings, modifications in tool edge geometry, investigations into tool wear processes (both cutting and abrasive), the diagnostics and monitoring of machining processes, as well as the modeling and simulation of machining operations. Additionally, topics related to product quality, such as surface roughness, surface waviness, dimensional accuracy, and shape precision, are also explored.

Dr. Łukasz Żyłka
Dr. Paweł Lajmert
Dr. Andrzej Weremczuk
Dr. Jakub Matuszak
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 250 words) can be sent to the Editorial Office for assessment.

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. Applied Sciences 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 2400 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 roughness
  • surface waviness
  • dimensional accuracy
  • shape accuracy
  • tool wear
  • tool edge geometry
  • cutting fluids
  • machining strategies
  • machining parameters
  • machining diagnostics
  • process monitoring
  • process modeling
  • machining simulation

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Published Papers (3 papers)

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Research

29 pages, 5754 KB  
Article
Effect of Primary Cutting Edge Geometry on the End Milling of EN AW-7075 Aluminum Alloy
by Łukasz Żyłka, Rafał Flejszar and Luis Norberto López de Lacalle
Appl. Sci. 2025, 15(24), 12962; https://doi.org/10.3390/app152412962 - 9 Dec 2025
Viewed by 304
Abstract
This study investigates vibration signals generated during end milling of thin-walled EN AW-7075 aluminum alloy components using a set of 24 tools with distinct cutting edge microgeometries. Five characteristic parameters describing the dynamic response of the process, including both energy-related and statistical indicators, [...] Read more.
This study investigates vibration signals generated during end milling of thin-walled EN AW-7075 aluminum alloy components using a set of 24 tools with distinct cutting edge microgeometries. Five characteristic parameters describing the dynamic response of the process, including both energy-related and statistical indicators, were extracted and analyzed. The results clearly demonstrate the critical influence of tool microgeometry on process dynamics. In particular, the introduction of an additional zero-clearance flank land at the cutting edge proved decisive in suppressing vibrations. For the most favorable geometries, the root mean square (RMS) value of vibration was reduced by more than 50%, while the spectral power density (PSD) decreased by up to 70–75% compared with the least favorable configurations. Simultaneously, both time- and frequency-domain responses exhibited complex and irregular patterns, highlighting the limitations of intuitive interpretation and the need for multi-parameter evaluation. To enable a synthetic comparison of tools, the Vibration Severity Index (VSI), which integrates RMS and kurtosis into a single composite metric, was introduced. VSI-based ranking allowed the clear identification of the most dynamically stable geometry. For the selected tool, additional analysis was conducted to evaluate the influence of cutting parameters, namely feed per tooth and radial depth of cut. The results showed that the most favorable dynamic behavior was achieved at a feed of 0.08 mm/tooth and a radial depth of cut of 1.0 mm, whereas boundary conditions resulted in higher kurtosis and a more impulsive signal structure. Overall, the findings confirm that properly engineered cutting-edge microgeometry, especially the formation of additional zero-clearance flank land significantly enhances the dynamic of thin-wall milling, demonstrating its potential as an effective strategy for vibration suppression and process optimization in precision machining of lightweight structural materials. Full article
(This article belongs to the Special Issue Advances in Precision Machining Technology)
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24 pages, 4471 KB  
Article
Analysis of the Effect of Machining Parameters on the Cutting Tool Deflection in Curved Surface Machining
by Michał Leleń, Magdalena Zawada-Michałowska, Paweł Pieśko, Katarzyna Biruk-Urban, Jerzy Józwik, Jarosław Korpysa, Kamil Anasiewicz, Witold Habrat and Joanna Lisowicz
Appl. Sci. 2025, 15(20), 11013; https://doi.org/10.3390/app152011013 - 14 Oct 2025
Viewed by 729
Abstract
The aim of this study is to investigate the impact of machining parameters on the deflection of a cutting tool (i.e., end mill) in the milling of a surface with a curvilinear profile. Test samples were made of aluminium alloy EN AW-7075 T651. [...] Read more.
The aim of this study is to investigate the impact of machining parameters on the deflection of a cutting tool (i.e., end mill) in the milling of a surface with a curvilinear profile. Test samples were made of aluminium alloy EN AW-7075 T651. Experiments were conducted using the Gocator 2530 laser line profile sensor for real-time measurement of dynamic tool displacement with an inspection speed up to 10 kHz at resolution ranging from 0.028 to 0.054 mm. Response surface methodology was used. Five main technological factors were analysed: cutting speed, feed per tooth (cutting parameters), amplitude, term (curvilinear profile parameters), and the number of flutes (end mill parameter). Obtained data were filtered and visualised as 3D plots. The results showed that cutting speed and amplitude had the greatest impact on tool deflection, while feed per tooth also played a significant role in process stability. In particular, the use of tools with a higher number of flutes led to a considerable reduction in tool deflection, confirming their positive effect on the stability of the machining process. These findings may serve as a basis for the optimisation of machining parameters by taking into account the dynamic deformation of cutting tools. Full article
(This article belongs to the Special Issue Advances in Precision Machining Technology)
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20 pages, 3369 KB  
Article
Machinability Evaluation of PM Vanadis 4 Extra Steel Under Varying Milling Conditions
by Jarosław Tymczyszyn, Artur Szajna, Anna Bazan and Grażyna Mrówka-Nowotnik
Appl. Sci. 2025, 15(17), 9256; https://doi.org/10.3390/app15179256 - 22 Aug 2025
Viewed by 1176
Abstract
Powder metallurgy tool steels, such as Vanadis 4 Extra (1.2210), are increasingly used in cold-work applications due to their superior hardness, wear resistance, and microstructural uniformity. Despite their growing popularity, there is limited data regarding their machinability, especially in milling processes. In this [...] Read more.
Powder metallurgy tool steels, such as Vanadis 4 Extra (1.2210), are increasingly used in cold-work applications due to their superior hardness, wear resistance, and microstructural uniformity. Despite their growing popularity, there is limited data regarding their machinability, especially in milling processes. In this study, experimental milling tests were performed on Vanadis 4 Extra steel using AlCrN-coated carbide tools. A full factorial experimental design (34) was applied to investigate the effects of cutting speed, depth of cut, width of cut, and feed per tooth on cutting forces (Fx, Fy, Fz, Fc), surface roughness parameters (Ra, Rz), and tool wear. Cutting forces were measured using a Kistler dynamometer, and surface roughness was evaluated using a contact profilometer. Regression models were developed and statistically validated. The results indicate that depth of cut had the most significant influence on cutting force, while cutting speed had the greatest impact on surface roughness. Moderate correlation between cutting forces and roughness was observed, particularly under low-load conditions. SEM analysis revealed abrasive wear and chipping of the coating layer. The findings provide insights into the machinability of Vanadis 4 Extra and offer guidelines for optimizing milling parameters to enhance tool life and surface integrity. Full article
(This article belongs to the Special Issue Advances in Precision Machining Technology)
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