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Machines
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Machine Tools for Precision Machining: Design, Control and Prospects
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Machine Tools for Precision Machining: Design, Control and Prospects

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Advanced Manufacturing".

Deadline for manuscript submissions: 30 September 2025 | Viewed by 5961

Special Issue Editors

Dr. Yuwen Sun

E-Mail Website
Guest Editor
School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, China
Interests: tool path; sculptured surface; machining dynamics; adaptive machining; NC machining
Special Issues, Collections and Topics in MDPI journals
Dr. Shanglei Jiang

E-Mail Website
Guest Editor
School of Mechanical Engineering, Dalian Jiaotong University, Dalian 116024, China
Interests: machining dynamics; anti-vibration tool; machining process modeling and simulation

Special Issue Information

Dear Colleagues,

Precision machining has become essential to the manufacturing sector and has been found to create many critical parts for aerospace, electronics, and medical industries, among others. It generally involves a high-velocity machining process that makes parts requiring tight tolerances, high complexities, or both. This can be achieved through the use of advanced computerized machine tools with a high degree of repeatability and accuracy. As a basic tool for manufacturing the critical parts, high-precision multi-axis CNC machines are becoming indispensable in precision machining by producing different cutting effects to meet strict machining needs. At present, due to the continuous emergence of various new materials and new processes, complex material mechanisms, cumbersome manufacturing processes, and harsh processing conditions have put forward higher and higher performance requirements for machine tools. Therefore, precision machining requires the in-depth development of advanced theories and technologies, such as machine tool motion planning, error control and compensation, machining chatter prediction and suppression, cutter wear and chatter monitoring, bearing fault diagnosis, process parameter optimization, etc., to ensure that the required accuracy and stability are maintained in the face of evolving challenges.

Dr. Yuwen Sun
Dr. Shanglei Jiang
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. Machines 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 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.

Keywords

  • machine tool motion planning
  • error control and compensation
  • machining chatter prediction and suppression
  • cutter wear and chatter monitoring
  • bearing fault diagnosis
  • machining process modeling and simulation
  • process parameter optimization

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Published Papers (4 papers)

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Research

15 pages, 2342 KiB  
Article
Numerical Modeling and Optimization of Nomex Honeycomb Core Milling: Influence of Longitudinal and Longitudinal–Torsional Ultrasonic Vibrations
by Tarik Zarrouk, Mohammed Nouari and Hicham Bouali
Machines 2025, 13(2), 99; https://doi.org/10.3390/machines13020099 - 27 Jan 2025
Viewed by 567
Abstract
Nomex honeycomb structures (NHCs) have currently experienced significant development, mainly in the aeronautics, aerospace, marine, and automotive sectors. This expansion raises noteworthy challenges related to the improvement of machining excellence, necessitating the use of particular cutting tools and adapted techniques. With this in [...] Read more.
Nomex honeycomb structures (NHCs) have currently experienced significant development, mainly in the aeronautics, aerospace, marine, and automotive sectors. This expansion raises noteworthy challenges related to the improvement of machining excellence, necessitating the use of particular cutting tools and adapted techniques. With this in mind, experimental studies were conducted to analyze the specificities of Nomex honeycomb cores milling by integrating longitudinal ultrasonic vibrations along the cutting tool rotation axis (UCK). However, the high tool speed and the unreachability of the tool-workpiece interface complicate the direct observation of the cutting process. To overcome these challenges, a 3D numerical model was developed to simulate the milling of composite honeycomb structures by integrating longitudinal and longitudinal–torsional ultrasonic vibrations. This model was developed by Abaqus/Explicit software, version 2017. The obtained results indicate that the integration of longitudinal–torsional vibrations allows a reduction in cutting forces by up to 28%, a reduction in the accumulation of material in front of the cutting tool, with a maximum reduction of 30%, and an improvement in the quality of the machined surface. Full article
(This article belongs to the Special Issue Machine Tools for Precision Machining: Design, Control and Prospects)
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18 pages, 15291 KiB  
Article
Optimization of Tool Wear and Cutting Parameters in SCCO2-MQL Ultrasonic Vibration Milling of SiCp/Al Composites
by Huiping Zhang, Bowen Wang, Liqiang Qu and Xinran Wang
Machines 2024, 12(9), 646; https://doi.org/10.3390/machines12090646 - 14 Sep 2024
Cited by 1 | Viewed by 1243
Abstract
Silicon carbide particle-reinforced aluminum matrix (SiCp/Al) composites are significant lightweight metal matrix composites extensively utilized in precision instruments and aerospace sectors. Nevertheless, the inclusion of rigid SiC particles exacerbates tool wear in mechanical machining, resulting in a decline in the quality of surface [...] Read more.
Silicon carbide particle-reinforced aluminum matrix (SiCp/Al) composites are significant lightweight metal matrix composites extensively utilized in precision instruments and aerospace sectors. Nevertheless, the inclusion of rigid SiC particles exacerbates tool wear in mechanical machining, resulting in a decline in the quality of surface finishes. This work undertakes a comprehensive investigation into the problem of tool wear in SiCp/Al composite materials throughout the machining process. Initially, a comprehensive investigation was conducted to analyze the effects of cutting velocity vc, feed per tooth fz, milling depth ap, and milling width ae on tool wear during high-speed milling under SCCO2-MQL (Supercritical Carbon Dioxide Minimum Quantity Lubrication) ultrasonic vibration conditions. The results show that under the condition of SCCO2-MQL ultrasonic vibration, proper control of milling parameters can significantly reduce tool wear, extend tool service life, improve machining quality, and effectively reduce blade breakage and spalling damage to the tool, reduce abrasive wear and adhesive wear, and thus significantly improve the durability of the tool. Furthermore, a prediction model for tool wear was developed by employing the orthogonal test method and multiple linear regression. The model’s relevance and accuracy were confirmed using F-tests and t-tests. The results show that the model can effectively predict tool wear, among which cutting velocity vc and feed rate fz are the key parameters affecting the prediction accuracy. Finally, a genetic algorithm was used to optimize the milling parameters, and the optimal parameter combination (vc = 60.00 m/min, fz = 0.08 mm/z, ap = 0.20 mm) was determined, and the optimized milling parameters were tested. Empirical findings suggest that the careful selection of milling parameters can significantly mitigate tool wear, extend the lifespan of the tool, and enhance the quality of the surface. This work serves as a significant point of reference for the processing of SiCp/Al composite materials. Full article
(This article belongs to the Special Issue Machine Tools for Precision Machining: Design, Control and Prospects)
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17 pages, 6401 KiB  
Article
Study on Surface Characteristics and Work Hardening of SiCp/Al Composites by SCCO2-MQL Combined with Ultrasonic Vibration Milling
by Huiping Zhang, Yihan Tao, Yanlin Wu and Yongxin Li
Machines 2024, 12(5), 282; https://doi.org/10.3390/machines12050282 - 23 Apr 2024
Cited by 4 | Viewed by 1138
Abstract
This study investigated the milling of SiCp/Al composite materials using Polycrystalline Diamond (PCD) tools under various machining conditions, including dry cutting conditions, supercritical carbon dioxide (SCCO2) conditions, supercritical carbon dioxide cooling with minimum quantity lubrication (SCCO2-MQL) conditions, ultrasonic vibration [...] Read more.
This study investigated the milling of SiCp/Al composite materials using Polycrystalline Diamond (PCD) tools under various machining conditions, including dry cutting conditions, supercritical carbon dioxide (SCCO2) conditions, supercritical carbon dioxide cooling with minimum quantity lubrication (SCCO2-MQL) conditions, ultrasonic vibration conditions, and supercritical carbon dioxide cooling with minimum quantity lubrication combined with ultrasonic vibration conditions. The objective was to compare the surface roughness and morphology of the materials under different machining conditions. Furthermore, under dry cutting conditions and SCCO2-MQL combined with ultrasonic vibration, the effects of different milling parameters on the surface roughness and morphology of SiCp/Al composite materials were investigated through a univariate experiment. Microhardness tests were carried out on the machined workpieces to explore the influence of process conditions and milling parameters on work hardening. The experimental results indicate that among all the tested machining conditions, the SCCO2-MQL in combination with the ultrasonic vibration process significantly reduced the surface roughness of the material. When the milling speed was increased from 40 m/min to 120 m/min, both the surface roughness and the degree of work hardening first increased and then decreased. As the feed rate or cutting depth increased, the degree of work hardening also increased. Therefore, under SCCO2-MQL combined with ultrasonic vibration conditions, it is recommended to use a milling speed of more than 60 m/min and avoid using high feed rates and cutting depths in order to optimize the machining performance. Full article
(This article belongs to the Special Issue Machine Tools for Precision Machining: Design, Control and Prospects)
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17 pages, 6269 KiB  
Article
Investigation of Force-Controlled Polishing of Complex Curved PMMA Parts on a Machining Center
by Xiangran Meng, Yingpeng Wang, Xiaolong Yin, Haoyu Fu, Shuoxue Sun and Yuwen Sun
Machines 2024, 12(4), 259; https://doi.org/10.3390/machines12040259 - 14 Apr 2024
Viewed by 1637
Abstract
During the polishing process of complex curved PMMA parts, the polishing force is an important factor affecting the surface quality and optical performance. In this paper, a force-controlled polishing device integrated into a machining center to maintain the polishing force is investigated. In [...] Read more.
During the polishing process of complex curved PMMA parts, the polishing force is an important factor affecting the surface quality and optical performance. In this paper, a force-controlled polishing device integrated into a machining center to maintain the polishing force is investigated. In order to achieve the real-time active control of the polishing force, the linear voice coil motor and force sensors are used for motion and measurement. A compact structure was designed to couple the linear motion of the voice coil motor with the rotation for polishing. The force-controlled polishing system with a high real-time hardware architecture was developed to perform complex curved polishing path movement with precise force control. Next, the polishing force between the device and the workpiece was analyzed to obtain the mathematical model of the device. Considering the impact during the approaching phase of polishing, a fuzzy PI controller was proposed to reduce the overshoot and response time. To implement the control method, the controller model was established on Simulink and the control system was developed based on TwinCAT 3 software with real-time computing capability. Finally, a polishing experiment involving a complex curved PMMA part was conducted by a force-controlled polishing device integrated into a five-axis machining center. The results show that the device can effectively maintain the polishing force to improve surface quality and optical performance. Full article
(This article belongs to the Special Issue Machine Tools for Precision Machining: Design, Control and Prospects)
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