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JMMP
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Advanced Design, Manufacturing, and Applications of Precision Machine Tools
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Advanced Design, Manufacturing, and Applications of Precision Machine Tools

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 30 June 2026 | Viewed by 3862

Special Issue Editor

Dr. Jun Zha

E-Mail Website
Guest Editor
School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, China
Interests: hydrostatic bearings; machine tools; precision machining; measurement
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The pursuit of ultra-high precision and efficiency in modern manufacturing demands continuous innovation in machine tool design, fabrication, and application. This Special Issue focuses on cutting-edge technologies in precision machine tool development, including high-stiffness structural design, thermal error compensation, vibration suppression, advanced control systems, and smart monitoring. Additionally, it explores their applications in critical sectors such as aerospace, automotives, microelectronics, and medical device manufacturing.

We invite original research and reviews addressing challenges in machining accuracy, dynamic performance optimization, energy-efficient machining, and digital twin integration. Contributions may cover theoretical advances, experimental validations, or industrial case studies.

This issue aims to foster discussions on emerging trends, such as AI-driven process optimization and sustainable precision manufacturing, providing a platform for researchers and engineers to share breakthroughs.

You may choose our Joint Special Issue in Machines.

Dr. Jun Zha
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 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. Journal of Manufacturing and Materials Processing 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 1800 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

  • precision machine tools
  • thermal error compensation
  • vibration control
  • high-performance machining
  • digital twin
  • smart manufacturing
  • AI-driven process optimization
  • ultra-precision machining
  • structural optimization
  • energy-efficient machining

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (4 papers)

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Research

31 pages, 4237 KB  
Article
Cutting Force Mechanisms in Drilling 90MnCrV8 Tool Steel: ANOVA and Theoretical Insights
by Jaroslava Fulemová, Josef Sklenička, Jan Hnátík, Miroslav Gombár, Jindřich Sýkora, Michal Povolný and Adam Lukáš
J. Manuf. Mater. Process. 2026, 10(1), 38; https://doi.org/10.3390/jmmp10010038 - 20 Jan 2026
Viewed by 453
Abstract
This study investigates the influence of tool geometry and cutting parameters on thrust forces and process stability during the drilling of 90MnCrV8, a hard and wear-resistant tool steel. The objective was to identify the dominant and interactive effects of feed per revolution ( [...] Read more.
This study investigates the influence of tool geometry and cutting parameters on thrust forces and process stability during the drilling of 90MnCrV8, a hard and wear-resistant tool steel. The objective was to identify the dominant and interactive effects of feed per revolution (frev), nominal tool diameter (D), cutting speed (vc), and geometry angles (εr, αo, ωr) on the thrust force (Ff). Experimental data were evaluated using analysis of variance (ANOVA) to determine statistical significance and effect size (η2), supported by theoretical models by Kienzle, Merchant, Oxley and Zorev to explain observed physical trends. Feed per revolution had the most decisive influence on thrust force (η2 = 0.690; p < 0.001), followed by tool diameter (D; η2 = 0.188). Geometric parameters showed secondary yet significant effects, mainly on stress distribution and chip evacuation. The interaction between D and frev produced a multiplicative force increase, while the combination of frev and helix angle (ωr) reduced friction at higher feeds. Cutting speed had a minor effect (η2 = 0.007), suggesting limited thermal softening. The findings confirm that drilling hard steels is primarily governed by the energy of plastic deformation. Full article
(This article belongs to the Special Issue Advanced Design, Manufacturing, and Applications of Precision Machine Tools)
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20 pages, 2969 KB  
Article
Influence of Tool Clearance Angle and Cutting Conditions on Tool Life When Turning Ti-6Al-4V—Design of Experiments Approach
by Adam Lukáš, Miroslav Gombár, Jindřich Sýkora, Josef Sklenička, Jaroslava Fulemová and Jan Hnátík
J. Manuf. Mater. Process. 2026, 10(1), 15; https://doi.org/10.3390/jmmp10010015 - 31 Dec 2025
Viewed by 890
Abstract
The titanium alloy Ti-6Al-4V is widely used in the aerospace, medical, and automotive industries; however, its machining remains challenging due to its low thermal conductivity and high chemical reactivity. This study investigates the influence of the tool clearance angle on tool wear during [...] Read more.
The titanium alloy Ti-6Al-4V is widely used in the aerospace, medical, and automotive industries; however, its machining remains challenging due to its low thermal conductivity and high chemical reactivity. This study investigates the influence of the tool clearance angle on tool wear during the turning of Ti-6Al-4V under wet cutting conditions. A Design of Experiments (DoE) approach was employed, varying the clearance angle, cutting speed, and feed rate to determine their effects on tool wear. Tool wear was analysed using 3D topography measurements. Regression analysis was used to evaluate the experimental data with the main objective of quantifying the impact of the individual factors and their interactions, resulting in the development of a predictive statistical model. The model’s accuracy was assessed using the coefficient of determination (R2) and the adjusted coefficient of determination (R2adj). The results demonstrate that the clearance angle has a significant impact on crater wear formation and overall tool life. An optimised moderate clearance angle reduces tool degradation, enhances tool life, and improves the surface integrity of the machined component. Full article
(This article belongs to the Special Issue Advanced Design, Manufacturing, and Applications of Precision Machine Tools)
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26 pages, 6447 KB  
Article
Comprehensive Analysis of Ball End Mill Geometrical Modification with Statistical Validation
by Nicolas Paulovič, Ivan Buranský, Rudolf Zaujec and Janette Kotianová
J. Manuf. Mater. Process. 2026, 10(1), 7; https://doi.org/10.3390/jmmp10010007 - 26 Dec 2025
Viewed by 747
Abstract
This work presents a comprehensive analysis of ball-end mill geometrical modification, with emphasis on surface quality and stability of the machining process. The study combines predictive modeling, analytical simulations, and experimental validation to evaluate the influence of cutting tool radius and process parameters [...] Read more.
This work presents a comprehensive analysis of ball-end mill geometrical modification, with emphasis on surface quality and stability of the machining process. The study combines predictive modeling, analytical simulations, and experimental validation to evaluate the influence of cutting tool radius and process parameters on surface roughness. A composite factorial design of experiments was implemented to systematically investigate radius, stepover height, and inclination angle. Surface roughness was measured using a contact stylus profilometer, with secondary validation of selected samples by three-dimensional (3D) optical microscopy, ensuring robust verification of experimental outcomes. In addition, a two-dimensional (2D) computer-aided design (CAD)-based simulation model was developed to reconstruct toolpath overlaps and calculate roughness parameters for comparison. The predictive models were statistically compared with experimental and simulation results, showing consistent trends, while also highlighting deviations possibly due to process dynamics and cutting tool stability. Results indicate that ball-end mills with smaller radii demonstrate higher sensitivity to chatter and surface instability, while larger radii improve consistency as well as achievable roughness values. The combined methodology provides both practical and theoretical insights into optimizing cutting tool geometry for precision milling. The findings are relevant for cutting tool designers and manufacturing engineers seeking to balance productivity, cost, and surface integrity in finishing operations. Full article
(This article belongs to the Special Issue Advanced Design, Manufacturing, and Applications of Precision Machine Tools)
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17 pages, 4812 KB  
Article
Turn Milling of Inconel 718 Produced via Additive Manufacturing Using HVOF and DMLS Methods
by Michal Povolný, Michal Straka, Miroslav Gombár, Jan Hnátík, Jan Kutlwašer, Josef Sklenička and Jaroslava Fulemová
J. Manuf. Mater. Process. 2025, 9(12), 399; https://doi.org/10.3390/jmmp9120399 - 4 Dec 2025
Cited by 1 | Viewed by 1022
Abstract
Additive and coating technologies, such as high-velocity oxy-fuel (HVOF) thermal spraying and direct metal laser sintering (DMLS), often require extensive post-processing to meet dimensional and surface quality requirements, which remains challenging for nickel-based superalloys such as Inconel 718. This study presents the design [...] Read more.
Additive and coating technologies, such as high-velocity oxy-fuel (HVOF) thermal spraying and direct metal laser sintering (DMLS), often require extensive post-processing to meet dimensional and surface quality requirements, which remains challenging for nickel-based superalloys such as Inconel 718. This study presents the design and topology optimisation of a cutting tool with a linear cutting edge, capable of operating in turn-milling or turning modes, offering a viable alternative to conventional grinding. A non-optimised tool served as a baseline for comparison with a topology-optimised variant improving cutting-force distribution and stiffness-to-mass ratio. Finite element analyses and experimental turn-milling trials were performed on DMLS and HVOF Inconel 718 using carbide and CBN inserts. The optimised tool achieved significantly reduced roughness values: for DMLS, Ra decreased from 0.514 ± 0.069 µm to 0.351 ± 0.047 µm, and for HVOF from 0.606 ± 0.069 µm to 0.407 ± 0.069 µm. Rz was similarly improved, decreasing from 4.234 ± 0.343 µm to 3.340 ± 0.439 µm (DMLS) and from 5.349 ± 0.552 µm to 4.521 ± 0.650 µm (HVOF). The lowest measured Ra, 0.146 ± 0.030 µm, was obtained using CBN inserts at the highest tested cutting speed. All improvements were statistically significant (p < 0.005). No measurable tool wear was observed due to the small engagement and the use of a fresh cutting edge for each pass. The resulting surface quality was comparable to grinding and clearly superior to conventional turning. These findings demonstrate that combining topology optimisation with a linear-edge tool provides a practical and efficient finishing approach for additively manufactured and thermally sprayed Inconel 718 components. Full article
(This article belongs to the Special Issue Advanced Design, Manufacturing, and Applications of Precision Machine Tools)
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