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Lubricants
Special Issues
High Performance Machining and Surface Tribology
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High Performance Machining and Surface Tribology

A special issue of Lubricants (ISSN 2075-4442).

Deadline for manuscript submissions: 31 December 2025 | Viewed by 2971

Special Issue Editors

Dr. Lai Hu

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Guest Editor
State Key Laboratory of Tribology in Advanced Equipment, Tsinghua University, Beijing 100084, China
Interests: friction and wear; grinding; ultra-precision/precision machining; surface integrity; bearings
Dr. Chen Yin

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Guest Editor
School of Data Science, City University of Hong Kong, Hong Kong 999077, China
Interests: machining signal processing and analysis; wear detection; surface quality control
Dr. Jun Wang

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Guest Editor
Aeronautics Advanced Manufacturing Center (CFAA), Universidad del País Vasco (UPV/EHU), Bizkaia Technology Park, Building 202, 48170 Zamudio, Spain
Interests: high-performance machining; EDM; development and optimization of machining processes; design and application of non-conventional manufacturing technologies; simulation-based performance enhancement

Special Issue Information

Dear Colleagues,

With the rapid changes in the market, the requirements for the performance of high-end equipment have become increasingly stringent. In the current manufacturing field, manufacturing enterprises face difficulties with the key parts of high-performance processing technology in high-end equipment such as aircraft, rockets and new energy vehicles. The operating environment of the key parts of high-end equipment is getting increasingly harsher, making their dimensional deviation and surface integrity requirements more stringent. High-performance machining, advanced machining technology, condition monitoring, surface integrity, interface tribology, surface macro- and micro-characteristics, etc., directly or indirectly affect the service life of the parts of high-end equipment. For example, machining vibration signals, acoustic emission signals, cutting force and thermal signals, power, current, voltage, etc., have a regular mapping relationship with surface wear morphology, friction peak value, roughness, stress, and crystal structure changes. Through the mapping of relationships, coupling problems among process parameters, process monitoring, and service life can be explored. This Special Issue will mainly focus on analyses of multi-source signal processing, the wear mechanisms of high-performance machined surfaces, and the surface wear characteristics of difficult-to-machine materials; it will also focus on analyses of a variety of macro- and micro-mechanism problems in high-performance machined surfaces from a tribological point of view. These studies will not only provide solutions for controlling the full-cycle production quality of high-end products but also solve multi-factor traceability problems that affect high-performance processing. These findings will not only provide a rich scientific basis for high-end-product manufacturers and researchers but also analytical means for research on the friction and wear mechanisms of high-performance machined surfaces. At the same time, it is hoped that this Special Issue will be significant in guiding the research of high-performance machining and surface wear in the future.

Dr. Lai Hu
Dr. Chen Yin
Dr. Jun Wang
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. Lubricants 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 2600 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

  • tribological properties of metal machined surfaces
  • tribological properties of EDM surfaces
  • micro-wear of EDM surfaces
  • special processing and surface tribology
  • high-performance machining tools and surface tribology
  • surface machining signals and tribology
  • machining vibration signals and surface tribology
  • machining acoustic signaling and surface tribology
  • multi-source signal processing and surface tribology
  • surface and wear characteristics of difficult-to-machine materials
  • monitoring and quality control of surface wear in high-performance machining
  • digital-twin applications of high-performance machining
  • theories, methods, and tools of high-performance machining

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Published Papers (4 papers)

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Research

19 pages, 31637 KiB  
Article
Effect of Bio-Based, Mixed Ester Lubricant in Minimum Quantity Lubrication on Tool Wear and Surface Integrity in Ultra-Precision Fly-Cutting of KDP Crystals
by Xuelian Yao, Feihu Zhang, Shuai Zhang, Jianfeng Zhang, Defeng Liao, Xiangyang Lei, Jian Wang and Jianbiao Du
Lubricants 2025, 13(4), 156; https://doi.org/10.3390/lubricants13040156 - 1 Apr 2025
Viewed by 322
Abstract
Potassium dihydrogen phosphate (KDP) crystals, vital for high-power laser systems, pose significant machining challenges due to their brittleness, low hardness, and hygroscopic properties. Achieving crack-free, high-precision surfaces is essential but complex. Single-point diamond fly-cutting (SPDF) is the primary method, yet it exposes tools [...] Read more.
Potassium dihydrogen phosphate (KDP) crystals, vital for high-power laser systems, pose significant machining challenges due to their brittleness, low hardness, and hygroscopic properties. Achieving crack-free, high-precision surfaces is essential but complex. Single-point diamond fly-cutting (SPDF) is the primary method, yet it exposes tools to high mechanical stress and heat, accelerating wear. In dry cutting, worn tools develop adhesive layers that detach, causing scratches and degrading surface quality. Traditional wet cutting improves surface finish but leaves residual fluids that contaminate the surface with metal ions, leading to optical degradation and fogging. To address these issues, this study explores mixed-fat-based minimum quantity lubrication (MQL) as a sustainable alternative, comparing two lubricants: biodegradable-base mixed ester lubrication (BBMEL) and hydrocarbon-based synthetic lubricant (HCBSL). A comprehensive evaluation method was developed to analyze surface roughness, tool wear, and subsurface damage under dry cutting, MQL-BBMEL, and MQL-HCBSL conditions. Experimental results show that MQL-BBMEL significantly enhances machining performance, reducing average surface roughness by 27.77% (Sa) and 44.77% (Sq) and decreasing tool wear by 25.16% compared to dry cutting, outperforming MQL-HCBSL. This improvement is attributed to BBMEL’s lower viscosity and higher proportion of polar functional groups, which form stable lubricating films, minimizing friction and thermal effects. Structural analyses confirm that MQL-BBMEL prevents KDP crystal deliquescence and surface fogging. These findings establish MQL-BBMEL as an eco-friendly, high-performance solution for machining brittle optical materials, offering significant advancements in precision machining for high-power laser systems. Full article
(This article belongs to the Special Issue High Performance Machining and Surface Tribology)
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29 pages, 29665 KiB  
Article
Experimental Research on the Effect of Thermophysical Characteristics of Cutting Fluid on Cutting Performance During Turning Ti-6Al-4V Alloy
by Xiaorong Zhou, Lin He, Sen Yuan, Jing Deng, Zebin Su, Jingdou Yang and Feilong Du
Lubricants 2025, 13(2), 90; https://doi.org/10.3390/lubricants13020090 - 17 Feb 2025
Cited by 1 | Viewed by 626
Abstract
Cutting fluid has been widely used to enhance the heat dissipation of cutting systems. However, whether cutting fluid can fully play its role is closely correlated with its thermophysical characteristics, such as viscosity, surface tension, etc. In this work, to study the effect [...] Read more.
Cutting fluid has been widely used to enhance the heat dissipation of cutting systems. However, whether cutting fluid can fully play its role is closely correlated with its thermophysical characteristics, such as viscosity, surface tension, etc. In this work, to study the effect of the thermophysical characteristics of cutting fluid on cutting performance, three green vegetable oils (semi-synthetic fluid (L1), rapeseed oil (L2), canola oil (L3)) were selected as cutting fluids of the MQL system, and differences in cutting performance were compared and analyzed under varied lubrication environments. Firstly, the thermophysical characteristics of the vegetable oils were determined by experimental methods. Afterwards, parameters, including tool wear, cutting force, and temperature, as well as the quality of machined workpieces, were selected to evaluate cutting performance, and essential reasons for the difference in cutting performance under varied lubrication environments were clarified. The results demonstrated that the cutting force, cutting temperature, and tool wear produced in the three MQL environments were lower than those in the dry cutting environment, while only the L1 and L2 MQL environments exhibited higher machined surface quality than the dry cutting environment. Moreover, obvious differences in cutting performance under the three MQL environments were also observed due to the different thermophysical characteristics of the three vegetable oils. The best cutting performance was achieved when L2 was used as the MQL cutting fluid. The efforts of this study will give an important reference for the choosing of green cutting fluid in the cutting process of difficult-to-cut materials and be of great significance for accelerating the development of green processing. Full article
(This article belongs to the Special Issue High Performance Machining and Surface Tribology)
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25 pages, 8306 KiB  
Article
Investigation of the Contact Characteristics of a Single-Nut Ball Screw Considering Geometric Errors
by Jun Liu, Huaxi Zhou, Xiaoyi Wang and Changguang Zhou
Lubricants 2025, 13(2), 57; https://doi.org/10.3390/lubricants13020057 - 29 Jan 2025
Viewed by 919
Abstract
As the critical performance index of ball screws, the contact characteristics have a significant influence on the lubricant properties, tribological properties, and wear properties of ball screws, which further directly affect the service life of ball screws. The non-uniform load distribution induced by [...] Read more.
As the critical performance index of ball screws, the contact characteristics have a significant influence on the lubricant properties, tribological properties, and wear properties of ball screws, which further directly affect the service life of ball screws. The non-uniform load distribution induced by geometric errors results in imbalances among balls along the nut, negatively impacting the service life of ball screws. This study focuses on the load distribution of single-nut ball screws under low-speed working conditions. This paper proposes a self-adjustable model of load distribution that considers the flexibility of the screw and nut with respect to the determination of the non-bearing ball. A refined model for axial stiffness is proposed to systematically analyze the influence of geometric errors on stiffness variations under various loading conditions. The results confirm the ability of the proposed model to reveal the static load distribution in view of geometric errors. The greatest discrepancy observed between the theoretical predictions and the experimental data was 9.22%. The numerical simulations demonstrate variation trends in the normal contact load, the loaded-ball number, and the axial deformation of a nut with geometric errors. Furthermore, the relationship between the axial stiffness of a single-nut ball screw and the geometric error is obtained. The self-adjustable model of load distribution is helpful for studying the carrying capacity of a single-nut ball screw. The findings of the study provide a definite reference for optimization of structural design and wear life prediction. Full article
(This article belongs to the Special Issue High Performance Machining and Surface Tribology)
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18 pages, 12905 KiB  
Article
Flow Characteristics and Experimental Verification of T-Groove Dry Gas Seal Under Different Flow States
by Lanxia Zhang, Xuexing Ding, Shipeng Wang and Shuai Zhang
Lubricants 2025, 13(1), 9; https://doi.org/10.3390/lubricants13010009 - 30 Dec 2024
Viewed by 670
Abstract
With the improvement of dry gas seal efficiency in high-parameter fields, the flow pattern of gas film lubrication is complicated. Based on gas lubrication theory, the Reynolds equation of compressible gas was established with a bidirectional T-groove dry gas seal as the research [...] Read more.
With the improvement of dry gas seal efficiency in high-parameter fields, the flow pattern of gas film lubrication is complicated. Based on gas lubrication theory, the Reynolds equation of compressible gas was established with a bidirectional T-groove dry gas seal as the research object. The Reynolds equation was solved to obtain a modified turbulent film pressure distribution law that affects gas lubrication. The effectiveness of the calculation program was verified by experimental tests. The results show that with an increase in operating parameters, the turbulence effect caused the gas film pressure fluctuation in the T-groove region to intensify, resulting in gas film flow instability. In addition, the inertia effect improved, which slowed down the leakage and affected the change law of stiffness and the rigid leakage ratio. When the fluid speed and gas pressure were low, the inertia effect could be ignored. When the groove depth was increased to 8 μm, the height difference between the trough and non-T-groove region became larger due to the combination of the turbulence and inertia effects. Further, when the gas film thickness was 3 μm, the opening force and gas film stiffness were high due to the dynamic pressure effect in the small film thickness groove. An increase in the gas film thickness weakened the turbulence effect and reduced the gas film pressure fluctuation. Full article
(This article belongs to the Special Issue High Performance Machining and Surface Tribology)
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