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Applied Sciences
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Precision Machining and Manufacturing
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Precision Machining and Manufacturing

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

Deadline for manuscript submissions: closed (20 August 2022) | Viewed by 10112

Special Issue Editor

Prof. Dr. Xiaohong Lu

E-Mail Website
Guest Editor
School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, China
Interests: precision machining; micro-milling; modeling; process simulation; FSW
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The “Precision Machining and Manufacturing” section is devoted to advances in scientific understanding of high-accuracy machining; metrology; and manufacturing of engineering components, mainly in metals, but also in composites, ceramics, and other structural/functional materials. This section takes an integrated approach to all subjects related to research, design, manufacture, performance validation, and application of high-precision machining and manufacturing, including fundamental and applied research and development in manufacturing processes, fabrication technology, and advanced measurement science. The scope includes precision-engineered systems and supporting metrology over the full range of length scales.

Prof. Dr. Xiaohong Lu
Guest Editor

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. 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.

Published Papers (7 papers)

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Research

19 pages, 5379 KiB  
Article
Point-by-Point-Contact-Based Approach to Compute Position and Orientation between Parts Assembled by Multiple Non-Ideal Planes
by Jian Zhang, Lihong Qiao, Zhicheng Huang and Nabil Anwer
Appl. Sci. 2022, 12(22), 11596; https://doi.org/10.3390/app122211596 - 15 Nov 2022
Cited by 2 | Viewed by 1084
Abstract
Position and orientation deviations (PODs), being affected by surface deviations, occur after parts are assembled, which directly affects the performance of mechanical products. Moreover, mechanical parts are generally assembled with multiple constraint planes, and the generated PODs are influenced by the type of [...] Read more.
Position and orientation deviations (PODs), being affected by surface deviations, occur after parts are assembled, which directly affects the performance of mechanical products. Moreover, mechanical parts are generally assembled with multiple constraint planes, and the generated PODs are influenced by the type of positioning. Therefore, the PODs of multiple planes should be computed in the design stage according to the predicted surface deviations, to control the product performance. However, even though the POD computation of multiple planes has been researched, the effects of surface deviations and multiple types of positioning cannot be considered simultaneously. To address this problem, this study proposes a point-by-point-contact-based approach. The six-point positioning principle is employed to determine the possible number of contact points on each mating plane. The surface deviations are modeled from the perspective of manufacturing errors. Furthermore, the contact points on each mating plane are determined successively using both the strategies of progressively approaching position and of the orientation and recursion of contact points. As a result, the PODs are acquired. The feasibility and usefulness of the proposed approach are verified through a case study. Herein, effects of surface deviations and multiple types of positioning on PODs are unified as contact point variations. Consequently, this approach is expected to assist with accurately controlling the POD influence on the performance of mechanical products in the design stage. Full article
(This article belongs to the Special Issue Precision Machining and Manufacturing)
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13 pages, 4370 KiB  
Article
Effect of Welding Sequence in Angular Distortion on Butt Joint GMAW Process
by Inês S. Afonso, Manuel Rodríguez Martín and João E. Ribeiro
Appl. Sci. 2022, 12(20), 10402; https://doi.org/10.3390/app122010402 - 15 Oct 2022
Cited by 2 | Viewed by 1566
Abstract
Over time, the industrial use of the welding process has grown in significance and is now one of the primary methods for joining metallic parts. During the welding process, metallurgical and structural modifications occur close to the welded joint. The thermal stresses and [...] Read more.
Over time, the industrial use of the welding process has grown in significance and is now one of the primary methods for joining metallic parts. During the welding process, metallurgical and structural modifications occur close to the welded joint. The thermal stresses and geometric distortions are undesirable, and they are a challenge to accurately forecast. Laboratory tests were conducted utilizing the GMAW method on S235JR steel as the base material with the goal of examining the impact of the welding sequence on angular distortion in butt joints when comparing three different welding sequences. Equipment that can determine coordinates in the operational space with metrological accuracy was used to measure distortions. As a result of metrological and statistical analyses, it was found that the sequence factor is shown to substantially influence the final distortions and that the symmetrical method results in less distortions followed by a one-step method. Full article
(This article belongs to the Special Issue Precision Machining and Manufacturing)
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12 pages, 3446 KiB  
Article
Study of Drilled Holes after a Cryogenic Machining in Glass Fiber-Reinforced Composites
by Rosario Domingo, Beatriz de Agustina and Jorge Ayllón
Appl. Sci. 2022, 12(20), 10275; https://doi.org/10.3390/app122010275 - 12 Oct 2022
Cited by 5 | Viewed by 1394
Abstract
Glass fiber-reinforced composites are widely used in industry, with machining operations frequently performed, drilling, in particular, for later assembly. Although there is a smaller increase in temperature during drilling in composites than in metals, further cooling of the tool can produce improvements in [...] Read more.
Glass fiber-reinforced composites are widely used in industry, with machining operations frequently performed, drilling, in particular, for later assembly. Although there is a smaller increase in temperature during drilling in composites than in metals, further cooling of the tool can produce improvements in some variables, such as thrust force, diameter, or surface roughness. This has been seen in studies where lower temperatures were achieved by cooling compressed air, reaching around −20 °C in plates of polyether-ether-ketone and polyamide, reinforced with glass fiber at 30% (PEEK-GF30 and PA-GF30, respectively). This paper analyzes the results of cryogenic drilling in plates of PEEK-GF30 and PA-GF30, specifically assessing thrust forces, diameter, and average surface roughness. The experimental methodology was carried out by monitoring thrust forces during cryogenic drilling using a piezoelectric dynamometer, measuring diameters with a coordinate measurement machine, and assessing surface quality with a roughness profilometer. During the cutting, the temperature of the cutting tool achieved a temperature near −120 °C from cooling with liquid nitrogen. Conducting an analytical and statistical study allowed us to determine the relationships between the measured variables and cutting conditions. Our results showed that cooling the tool during the drilling processes improved results of the cutting process. Full article
(This article belongs to the Special Issue Precision Machining and Manufacturing)
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15 pages, 3839 KiB  
Article
Linear Tool Path-Smoothing Method in High-Speed Machining Based on Error Feasible Area and Curvature Optimization
by Xuefeng Yang and Youpeng You
Appl. Sci. 2022, 12(19), 9443; https://doi.org/10.3390/app12199443 - 21 Sep 2022
Cited by 1 | Viewed by 1098
Abstract
Linear tool path is widely used in high-speed NC machining. However, the geometrical discontinuity of the corner between the linear tool paths will lead to fluctuations in speed, acceleration and jerk, which can excite machinery vibration and reduce the machining efficiency and surface [...] Read more.
Linear tool path is widely used in high-speed NC machining. However, the geometrical discontinuity of the corner between the linear tool paths will lead to fluctuations in speed, acceleration and jerk, which can excite machinery vibration and reduce the machining efficiency and surface quality. To solve these problems, a novel corner smoothing method based on error feasible area and curvature optimization is proposed in this paper. Compared with most traditional corner smoothing methods using higher-order curves with all control points lying in the straight segment and inside of the tool path, the proposed method constructs B-spline transition curves with smaller curvatures to smooth the corners by reasonably distributing the curve control points inside and outside the straight line segment of the tool path (i.e., error feasible area). Furthermore, the corner transition curve is optimized by the minimum curve curvature extreme to improve the smoothness of the corner transition curve and reduce fluctuation in the kinematic profiles while respecting the G3 continuity (i.e., curvature-smooth), transition length limits and the uniqueness of curvature extremum. Finally, the simulation results show that the proposed method can reduce the curvature value and improve the smoothness of the curve and the minimum transitional velocity of the corner, which means that it can enhance machining efficiency and weaken machining vibration. The feasibility and effectiveness of the method are also verified. Full article
(This article belongs to the Special Issue Precision Machining and Manufacturing)
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10 pages, 2649 KiB  
Article
Study on Surface Roughness of Sidewall When Micro-Milling LF21 Waveguide Slits
by Xiaohong Lu, Pengrong Hou, Yihan Luan, Xudong Sun, Jinhui Qiao and Yu Zhou
Appl. Sci. 2022, 12(11), 5415; https://doi.org/10.3390/app12115415 - 27 May 2022
Cited by 4 | Viewed by 1272
Abstract
The surface quality of the sidewall in waveguide antennae is important, especially surface roughness, which directly affects the electrical performance of the slotted waveguide antenna. Micro-milling is a potentially effective processing technique for the antenna. However, surface roughness has been difficult to guarantee [...] Read more.
The surface quality of the sidewall in waveguide antennae is important, especially surface roughness, which directly affects the electrical performance of the slotted waveguide antenna. Micro-milling is a potentially effective processing technique for the antenna. However, surface roughness has been difficult to guarantee within a reasonable accuracy range. In this study, orthogonal experiments of micro-milling LF21 waveguide slits were conducted. The results of the range analysis mainly sorted the factors that affected the surface roughness and also helped to determine how surface roughness could be kept at a minimum. The surface roughness was predicted by using the group method of data handling (GMDH). The importance of the applied GMDH was that it continuously adjusted the network structure according to the potential relationship between cutting parameters and the corresponding surface roughness, which helped determine the model most optimally fitted to the experimental data. This research can be used as a reference for selecting cutting parameters in micro-milling LF21. Full article
(This article belongs to the Special Issue Precision Machining and Manufacturing)
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24 pages, 7725 KiB  
Article
Improved Cutting Force Modelling in Micro-Milling Aluminum Alloy LF 21 Considering Tool Wear
by Xiaohong Lu, Chen Cong, Pengrong Hou, Kai Xv and Steven Y. Liang
Appl. Sci. 2022, 12(11), 5357; https://doi.org/10.3390/app12115357 - 25 May 2022
Cited by 5 | Viewed by 1405
Abstract
Aluminum alloy LF 21 has a strong ability to reflect electromagnetic waves. LF 21 waveguide slit array structure is widely used in waveguide radar antenna. The stiffness of the slit array structure is relatively weak. So, the structure is prone to deformation under [...] Read more.
Aluminum alloy LF 21 has a strong ability to reflect electromagnetic waves. LF 21 waveguide slit array structure is widely used in waveguide radar antenna. The stiffness of the slit array structure is relatively weak. So, the structure is prone to deformation under the cutting force in the conventional milling process. Micro-milling technology can realize high-precision machining of mesoscale parts/structures and is a potential effective machining technology for the waveguide slit array structure. However, the diameter of the micro-milling cutter is small, and the feed per tooth is comparable to the arc radius of the cutting edge, so the micro-milling cutter is prone to wear. In addition, the effects of elastic recovery of material, the minimum cutting thickness and friction of cutting dead zone on micro-milling force cannot be ignored. A simulation model of micro-milling aluminum alloy LF 21 processes based on DEFORM 3D is built by combining the theory of cutting and the technology of process simulation. Prediction of tool wear is achieved. The quantitative relationship between the arc radius of the cutting edge and tool wear is clarified for the first time. The authors built an improved cutting force model in micro-milling LF 21 considering tool wear and cutter runout with the minimum cutting thickness as the boundary. The validity of the built micro-milling force model is verified by experiments. Full article
(This article belongs to the Special Issue Precision Machining and Manufacturing)
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30 pages, 15877 KiB  
Article
Study on Surface Integrity and Surface Roughness Model of Titanium Alloy TC21 Milling Considering Tool Vibration
by Zhenyu Wang, Hongyu Li and Tianbiao Yu
Appl. Sci. 2022, 12(8), 4041; https://doi.org/10.3390/app12084041 - 16 Apr 2022
Cited by 3 | Viewed by 1677
Abstract
Due to its excellent strength, plasticity, and fracture toughness, titanium alloy has been widely used in the aerospace field. The specificity of its application environment places high demands on the surface quality of titanium alloy. In this paper, we study the effects of [...] Read more.
Due to its excellent strength, plasticity, and fracture toughness, titanium alloy has been widely used in the aerospace field. The specificity of its application environment places high demands on the surface quality of titanium alloy. In this paper, we study the effects of different lubrication methods on the microscopic topography, surface roughness, and microhardness of titanium alloy TC21 during the milling process. The lubrication methods include dry, high-pressure air cooling, and minimum quantity lubrication (MQL). Compared with dry milling and high-pressure air cooling conditions, the MQL environment can effectively suppress plastic deformation and surface defects of titanium alloy TC21. MQL is significant for improving the milling process of titanium alloy TC21. In addition, a surface roughness model considering milling vibration is developed. According to the results of orthogonal experiments, the prediction accuracy of the surface roughness model is acceptable, and the prediction errors are all below 20%. Full article
(This article belongs to the Special Issue Precision Machining and Manufacturing)
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