Special Issue "Surface Integrity in Machining"

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

Deadline for manuscript submissions: closed (31 May 2019)

Special Issue Editors

Guest Editor
Prof. Dr. Carsten Heinzel

Leibniz-Institute for Materials Engineering and MAPEX Center for Materials and Processes at the University of Bremen, Badgasteiner Str. 3, 28359 Bremen, Germany
Website | E-Mail
Interests: Cutting and Abrasive Machining; Optimization of Coolant Supply; Surface Integrity Aspects; Modelling and Optimization of Manufacturing Processes and Process Chains; Precision Engineering; Monitoring and Control of Machining Processes
Guest Editor
Dr. Daniel Meyer

Leibniz-Institute for Materials Engineering and MAPEX Center for Materials and Processes at the University of Bremen, Badgasteiner Str. 3, 28359 Bremen, Germany
Website | E-Mail
Interests: Surface Integrity, Mechanical Surface Treatment, Metalworking Fluids, Machining

Special Issue Information

Dear Colleagues,

The complex interrelations of manufacturing processes, surface and subsurface properties, and the functional performance of manufactured parts are of high relevance for both academia and industrial applications. The achievable surface integrity of a product is strongly influenced by the way the part was produced and is decisive for its functionality. Thus, understanding the effects of manufacturing processes such as machining, forming, additive manufacturing, and others with regard to the resulting condition of the surface and subsurface layers in terms of hardness, residual stress, microstructural alterations, or chemical changes is the aim of several studies. Worldwide leading experts are dealing with surface-integrity-related research and have contributed significantly to a knowledge-based manner to manufacture parts with superior functional performance. Hence, this Special Issue is devoted to recent work presenting new findings and interrelations focusing on manufacturing processes, the resulting surface integrity, and the influence on the functional performance.

We are particularly interested in (but not limited to) contributions that focus on topics such as:

  • Surface and subsurface properties after machining
  • Depth effects of different manufacturing processes
  • New approaches to generating advantageous surface integrity
  • Generating desired surface and subsurface states by inverse engineering
  • Advanced models and simulations revealing complex interrelations between processes and the surface integrity
  • Surface integrity of parts manufactured on an additive and subtractive basis
  • Functional performance by means of fatigue strength, wear resistance, corrosion behavior, and others with respect to manufactured surfaces
  • New metrology techniques to assess surface-integrity-related entities

Prof. Dr. Carsten Heinzel
Dr. Daniel Meyer
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 papers will be 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 quarterly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) is waived for well-prepared manuscripts submitted to this issue. 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 Integrity
  • Surface and Subsurface Properties
  • Functional Performance of Manufactured Parts

Published Papers (4 papers)

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Research

Open AccessArticle
Prediction of Ground Surfaces by Using the Actual Tool Topography
J. Manuf. Mater. Process. 2019, 3(2), 40; https://doi.org/10.3390/jmmp3020040
Received: 29 March 2019 / Revised: 9 May 2019 / Accepted: 9 May 2019 / Published: 13 May 2019
PDF Full-text (2871 KB)
Abstract
This paper presents a prediction model for ground surfaces that uses the actual grinding wheel topography to perform a grinding simulation. Precise knowledge of expected machined surfaces plays an important role in process planning. Here, the main criterion is the achievement of the [...] Read more.
This paper presents a prediction model for ground surfaces that uses the actual grinding wheel topography to perform a grinding simulation. Precise knowledge of expected machined surfaces plays an important role in process planning. Here, the main criterion is the achievement of the components’ function after manufacturing. Therefore, it is essential to consider the surface roughness to enable a function-orientated workpiece surface. The presented approach uses a real grinding tool topography, which is measured by a 3D laser triangulation sensor in the machine tool. After a data processing step, the measured topography is imported into a material removal simulation. A kinematic simulation of the realistic ground surface enables the data-based confirmation of the envelope profile theory for the first time. Full article
(This article belongs to the Special Issue Surface Integrity in Machining)
Open AccessArticle
Interplay of Process Variables in Magnetic Abrasive Finishing of AISI 1018 Steel Using SiC and Al2O3 Abrasives
J. Manuf. Mater. Process. 2019, 3(2), 29; https://doi.org/10.3390/jmmp3020029
Received: 29 December 2018 / Revised: 19 March 2019 / Accepted: 23 March 2019 / Published: 28 March 2019
PDF Full-text (6018 KB) | HTML Full-text | XML Full-text
Abstract
This paper investigates the underlying interplay between the key process parameters of magnetic abrasive finishing (MAF) in improving surface quality. The five process parameters considered were the working gap, rotational speed, feed rate, abrasive amount, and abrasive mesh when MAFed independently with two [...] Read more.
This paper investigates the underlying interplay between the key process parameters of magnetic abrasive finishing (MAF) in improving surface quality. The five process parameters considered were the working gap, rotational speed, feed rate, abrasive amount, and abrasive mesh when MAFed independently with two abrasive particles—SiC and Al2O3. A series of experiments were conducted with an in-house built MAF tool. Based on the main effect results, a model predicting roughness reduction was developed. Results show that surface quality improvement and the underlying dominant process parameters seem unique to the abrasive type used. When MAFed with SiC, the abrasive quantity and rotational speed influence the most. On the other hand, when MAFed with Al2O3, the trend is different to SiC, i.e., the abrasive mesh size and the working gap are dominant. The prediction model was well validated by independent experiments, indicating its accuracy in estimating and optimizing the process outcome. MAF is a simple process with a complex interplay between parameters. This is very crucial when abrasive type, size, and amount to be used are concerned, which warrants a deeper investigation in terms of underlying dynamics, interactions, and the deformation of abrasive, magnetic, and workpiece materials. Full article
(This article belongs to the Special Issue Surface Integrity in Machining)
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Open AccessArticle
Chip Morphology and Delamination Characterization for Vibration-Assisted Drilling of Carbon Fiber-Reinforced Polymer
J. Manuf. Mater. Process. 2019, 3(1), 23; https://doi.org/10.3390/jmmp3010023
Received: 15 February 2019 / Revised: 28 February 2019 / Accepted: 7 March 2019 / Published: 12 March 2019
PDF Full-text (9530 KB) | HTML Full-text | XML Full-text
Abstract
Carbon fiber-reinforced polymers (CFRP) are widely used in the aerospace industry. A new generation of aircraft is being built using CFRP for up to 50% of their total weight, to achieve higher performance. Exit delamination and surface integrity are significant challenges reported during [...] Read more.
Carbon fiber-reinforced polymers (CFRP) are widely used in the aerospace industry. A new generation of aircraft is being built using CFRP for up to 50% of their total weight, to achieve higher performance. Exit delamination and surface integrity are significant challenges reported during conventional drilling. Exit delamination influences the mechanical properties of machined parts and, consequently, reduces fatigue life. Vibration-assisted drilling (VAD) has much potential to overcome these challenges. This study is aimed at investigating exit delamination and geometrical accuracy during VAD at both low- and high-frequency ranges. The kinematics of VAD are used to investigate the relationship between the input parameters (cutting speed, feed, vibration frequency, and amplitude) and the uncut chip thickness. Exit delamination and geometrical accuracy are then evaluated in terms of mechanical and thermal load. The results show a 31% reduction in cutting temperature, as well as a significant enhancement in exit delamination, by using the VAD technology. Full article
(This article belongs to the Special Issue Surface Integrity in Machining)
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Open AccessArticle
Investigations on Material Loads during Grinding by Speckle Photography
J. Manuf. Mater. Process. 2018, 2(4), 71; https://doi.org/10.3390/jmmp2040071
Received: 6 September 2018 / Revised: 11 October 2018 / Accepted: 12 October 2018 / Published: 16 October 2018
Cited by 2 | PDF Full-text (3998 KB) | HTML Full-text | XML Full-text
Abstract
The knowledge of the loads occurring during a manufacturing process (e.g., grinding) and of the modifications remaining in the material is used in the concept of process signatures to optimize the manufacturing process and compare it with others (e.g., laser processing). The prerequisite [...] Read more.
The knowledge of the loads occurring during a manufacturing process (e.g., grinding) and of the modifications remaining in the material is used in the concept of process signatures to optimize the manufacturing process and compare it with others (e.g., laser processing). The prerequisite for creating a process signature is that the loads can be characterized during the running process. Due to the rough process conditions, until now there is no in-process technique to measure the loads in the form of displacements and strains in the machined boundary zone. For this reason, the suitability of speckle photography is demonstrated for in-process measurements of material loads in a grinding process without cooling lubricant and the measurement results are compared with finite element method (FEM) simulations. As working hypothesis for the simulation it is assumed, that dry grinding is a purely thermally driven process. Despite the approximation by a purely thermal model with a constant heat source, the measured displacements differ only by a maximum of approximately 20% from the simulations. In particular, the strain measurements in feed speed direction are in good agreement with the simulation and support the thesis, that the dry grinding conditions used here lead to a primarily thermally affecting process. Full article
(This article belongs to the Special Issue Surface Integrity in Machining)
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