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JMMP
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Advances in High-Performance Machining Operations
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Advances in High-Performance Machining Operations

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

Deadline for manuscript submissions: 30 April 2025 | Viewed by 5917

Special Issue Editors

Dr. Guang Chen

E-Mail Website
Guest Editor
Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Tianjin 300354, China
Interests: cutting; surface integrity aspects; modeling of manufacturing processes; material constitutive modeling; bearing roller lapping; ultrasonic-assisted machining
Dr. Chunlei He

E-Mail Website
Guest Editor
Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Tianjin 300354, China
Interests: ultra-precision turning; surface roughness; surface topography; optical performance; precision milling; bearing roller lapping; diamond tool

Special Issue Information

Dear Colleagues,

High-performance machining operations comprise a variety of advanced manufacturing technologies which are proposed to machine components with high precision and machined surface integrity. High-performance machined parts can be found in products from the aerospace, automotive, and biomedical industries. In addition to cutting or thermal-mechanical processes to generate high surface integrity machined surfaces, numerical modeling approach is a fundamental and significant method to understand the micro-scale and instantaneous mechanism of material removal, surface or subsurface deformation, as well as process optimization.

In this Special Issue of JMMP, we are looking for recent findings which focus on advances in high-performance machining operations, including experimental studies and numerical modelings of cutting or thermal-mechanical deformation-induced machined surface integrity. Papers will be considered that show significant advancements in terms of the fundamental mechanisms of machining processes and necessary hybrid or novel machining processes which mainly aim to acquire high machined surface integrity. Numerical modelings of machining operations that are helpful for understanding the mechanism of microstructure evolution and micro-scale deformation behaviors with respect to machined surface integrity and process control will also be considered.

We are interested in contributions that focus on topics such as:

  • Advanced machining processes using novel or hybrid thermal-mechanical processes to achieve high performance, including high precision and machined surface integrity;
  • Theoretical and experimental studies of the mechanism of machined surface integrity achieved via advanced thermal-mechanical processes;
  • Numerical modeling of machined surface integrity considering microstructure evolution and the effects of microstructure on mechanical behaviors;
  • Studies focused on the combined effect of material, thermal-mechanical deformation processes and surface integrity using an advanced surface modification operation.

Dr. Guang Chen
Dr. Chunlei He
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. Journal of Manufacturing and Materials Processing 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 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

  • machining
  • surface integrity
  • numerical modeling
  • microstructure evolution
  • thermal-mechanical behaviors
  • surface modification

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Published Papers (3 papers)

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Research

20 pages, 10195 KiB  
Article
Finite Element Simulation of Ti-6Al-4V Alloy Machining with a Grain-Size-Dependent Constitutive Model Considering the Ploughing Effect Under MQL and Cryogenic Conditions
by Guang Chen, Zhuoyang Wu, James Caudill and I. S. Jawahir
J. Manuf. Mater. Process. 2024, 8(6), 239; https://doi.org/10.3390/jmmp8060239 - 28 Oct 2024
Viewed by 814
Abstract
The finite element modeling method has been widely applied in the modeling of the cutting process to characterize the instantaneous and microscale deformation mechanism that was difficult to obtain using physical experiments. The lubrication and cooling conditions, such as minimum quantity lubrication and [...] Read more.
The finite element modeling method has been widely applied in the modeling of the cutting process to characterize the instantaneous and microscale deformation mechanism that was difficult to obtain using physical experiments. The lubrication and cooling conditions, such as minimum quantity lubrication and cryogenic liquid nitrogen, affect the thermo-mechanical behaviors and machined surface integrity in the cutting process. In this work, a grain-size-dependent constitutive model was used to model orthogonal cutting for Ti-6Al-4V alloy with MQL and LN2 conditions. The cutting forces and chip morphologies that were measured in the cutting experiments of Ti-6Al-4V alloy were used to validate the simulated forces. The relative errors between the measured and simulated principal forces were less than 8%, while the relative errors of thrust forces were less than 19%. The predicted chip morphologies and surface grain refinement agreed well with the experimental results under the conditions with different uncut chip thicknesses and edge radii. Additionally, the relationship between the plastic displacement and grain refinement, as well as the microhardness and residual stresses under MQL and cryogenic conditions, were discussed. This work provides an effective modeling method for the orthogonal cutting of Ti-6Al-4V alloy to understand the mechanism of the plastic deformation and machined surface integrity under the MQL and LN2 conditions. Full article
(This article belongs to the Special Issue Advances in High-Performance Machining Operations)
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23 pages, 10615 KiB  
Article
Numerical Modeling of Cutting Characteristics during Short Hole Drilling: Part 2—Modeling of Thermal Characteristics
by Michael Storchak, Thomas Stehle and Hans-Christian Möhring
J. Manuf. Mater. Process. 2024, 8(1), 13; https://doi.org/10.3390/jmmp8010013 - 13 Jan 2024
Cited by 1 | Viewed by 1818
Abstract
The modeling of machining process characteristics and, in particular, of various cutting processes occupies a significant part of modern research. Determining the thermal characteristics in short hole drilling processes by numerical simulation is the object of the present study. For different contact conditions [...] Read more.
The modeling of machining process characteristics and, in particular, of various cutting processes occupies a significant part of modern research. Determining the thermal characteristics in short hole drilling processes by numerical simulation is the object of the present study. For different contact conditions of the workpiece with the drill cutting inserts, the thermal properties of the machined material were determined. The above-mentioned properties and parameters of the model components were established using a three-dimensional finite element model of orthogonal cutting. Determination of the generalized values of the machined material thermal properties was performed by finding the set intersection of individual properties values using a previously developed software algorithm. A comparison of experimental and simulated values of cutting temperature in the workpiece points located at different distances from the drilled hole surface and on the lateral clearance face of the drill outer cutting insert shows the validity of the developed numerical model for drilling short holes. The difference between simulated and measured temperature values did not exceed 22.4% in the whole range of the studied cutting modes. Full article
(This article belongs to the Special Issue Advances in High-Performance Machining Operations)
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22 pages, 5382 KiB  
Article
Numerical Modeling of Cutting Characteristics during Short Hole Drilling: Modeling of Kinetic Characteristics
by Michael Storchak, Thomas Stehle and Hans-Christian Möhring
J. Manuf. Mater. Process. 2023, 7(6), 195; https://doi.org/10.3390/jmmp7060195 - 4 Nov 2023
Cited by 5 | Viewed by 2467
Abstract
Analyzing the cutting process characteristics opens up significant opportunities to improve various material machining processes. Numerical modeling is a well-established, powerful technique for determining various characteristics of cutting processes. The developed spatial finite element model of short hole drilling is used to determine [...] Read more.
Analyzing the cutting process characteristics opens up significant opportunities to improve various material machining processes. Numerical modeling is a well-established, powerful technique for determining various characteristics of cutting processes. The developed spatial finite element model of short hole drilling is used to determine the kinetic characteristics of the machining process, in particular, the components of cutting force and cutting power. To determine the component model parameters for the numerical model of drilling, the constitutive equation parameters, and the parameters of the contact interaction between the drill and the machined material on the example of AISI 1045 steel machining, the orthogonal cutting process was used. These parameters are determined using the inverse method. The DOE (Design of Experiment) sensitivity analysis was applied as a procedure for determining the component models parameters, which is realized by multiple simulations using the developed spatial FEM model of orthogonal cutting and the subsequent determination of generalized values of the required parameters by finding the intersection of the individual value sets of these parameters. The target values for the DOE analysis were experimentally determined kinetic characteristics of the orthogonal cutting process. The constitutive equation and contact interaction parameters were used to simulate the short hole drilling process. The comparison of experimentally determined and simulated values of the kinetic characteristics of the drilling process for a significant range of cutting speed and drill feed changes has established their satisfactory coincidence. The simulated value deviation from the corresponding measured characteristics in the whole range of cutting speed and drill feed variation did not exceed 23%. Full article
(This article belongs to the Special Issue Advances in High-Performance Machining Operations)
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