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Research on Metal Cutting, Casting, Forming, and Heat Treatment

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 September 2025 | Viewed by 6600

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Special Issue Editors

Dr. Hongchao Ji

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Guest Editor

1. College of Mechanical Engineering, North China University of Science and Technology, Tangshan 063210, China
2. School of Materials Science and Engineering, Zhejiang University, Hangzhou 310030, China
Interests: metal plastic processing theory; technology and equipment; modeling and simulation of the whole process of plastic forming multi-field coupling; lightweight forming manufacturing technology of auto parts; carbon fiber material forming process and equipment
Special Issues, Collections and Topics in MDPI journals

Dr. Xuefeng Tang

E-Mail Website
Guest Editor

Associate Professor, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
Interests: intelligent plastic forming; crystal plasticity; microforming; on-line process monitor and decision
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Zhen Jia

E-Mail Website
Guest Editor

School of Aerospace Engineering, Shenyang Aerospace University, Shenyang, China
Interests: metal plastic forming theory; technology and equipment; modeling and simulation of the whole process of plastic forming multi-field coupling; lightweight forming manufacturing technology of auto parts

Special Issue Information

Dear Colleagues,

We are pleased to invite you to publish original research articles, review articles, and short memos related to “Research on Metal Cutting, Casting, Forming, and Heat Treatment”. The focus of the contributed papers may be either on metal-cutting processing, casting, forming, and heat treatment, which are relevant to practical analysis or industrial applications, such as experimental, numerical, optimization, or mathematical approaches. A hybrid approach analysis is encouraged.

In this Special Issue, articles regarding innovation in metal cutting, casting, forming, and heat treatment with various engineering materials are sought, especially those focused on micro-structure evolution, phase structure, changes in mechanical properties, and residual stress, to inform readers about recent research development activities and the latest ongoing research, or the current state of the art. Therefore, original research and unpublished materials that are concerned with the following subjects are requested:

Advances in traditional metal cutting (turning, milling, drilling, and boring), non-traditional cutting, hybrid cutting, vibration cutting, non-metallic cutting, and composite cutting.

Metallic/nonmetallic materials used in forming processes such as sheet metal forming, powder forming, bulk-forming, micro-forming, plastic deformation due to forming, tribology in the forming process, and innovative forming technology, such as incremental forming, laser forming, and hydroforming.

Casting technology, novel molding technology, moldless casting, casting formation, lost foam casting, molding technique, and iced casting forming.

Heat treatment (annealing, induction heating, surface hardening, quenching, etc.), laser/electron beam heat treatment, plasma treatment, surface treatment, surface characterization, and digitalized heat treatment, including online monitoring.

Rolling, shot peening (shot peening, blast peening, pressure peening, etc.), and forging and joining or welding technology.

Dr. Xuefeng Tang
Dr. Hongchao Ji
Prof. Dr. Zhen Jia
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. Materials 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 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

metal cutting
non-traditional cutting
composite cutting
metal forming
micro-forming
casting
molding technology
heat treatment
surface characterization
microstructure
innovative forming technology
molding technique
mechanical peening
pressure peening

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Published Papers (6 papers)

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Research

Jump to: Review

18 pages, 11198 KiB

Open AccessArticle

Insight into the Common W-Shaped Uneven Solidification Profile in Slab Casting: From Mechanisms to Targeted Strategies

by Hao Geng, Feifei Yang, Shuaikang Xia, Pu Wang, Jinwen Jin and Jiaquan Zhang

Materials 2025, 18(8), 1867; https://doi.org/10.3390/ma18081867 - 18 Apr 2025

Viewed by 272

Abstract

This study elucidates the underlying formation mechanisms and mitigation strategies for the W-shaped solidification profile in slab continuous casting. Through the development of a multiphysics coupling numerical model, integrated with measured nozzle cooling characteristics in the secondary cooling zone, the effect of steel flow patterns in mold and non-uniform cooling conditions in the secondary cooling zone on solidifying shell evolution is systematically studied. A principal finding is that wide-face shell erosion, induced by both the radial expansion jet and the lower recirculation, constitutes the primary determinant of uneven shell thickness. An increase in the immersion depth and inclination angle of the nozzle side-hole exacerbates the non-uniformity of the solidified shell. Non-uniform cooling in the secondary cooling zone further amplifies the shell thickness differences, culminating in characteristic dumbbell-shaped solidified shell geometry. Strategic implementation of localized enhanced cooling on the wide face in the secondary cooling zone demonstrates significant improvement in shell uniformity, with implementation efficacy contingent upon a critical process window (Segments 1–6). These findings establish mechanistic foundations and deliver practical guidance for minimizing centerline segregation through optimized continuous casting parameter configuration. Full article

(This article belongs to the Special Issue Research on Metal Cutting, Casting, Forming, and Heat Treatment)

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31 pages, 7519 KiB

Open AccessArticle

An Experimental Investigation into Trochoidal Milling for High-Quality GFRP Machining

by Ondřej Bílek, Martin Řezníček, Andrzej Matras, Tomáš Solařík and Lubomír Macků

Materials 2025, 18(7), 1669; https://doi.org/10.3390/ma18071669 - 5 Apr 2025

Viewed by 1607

Abstract

This study investigates the effectiveness of trochoidal (adaptive) milling in machining Glass Fiber Reinforced Polymer (GFRP), emphasizing its potential advantages over conventional milling. Six coated solid carbide end mills, each with distinct geometries, were evaluated under identical conditions to assess the cutting forces, surface quality, dimensional accuracy, burr formation, chip size distribution, and tool wear. Trochoidal milling demonstrated shorter cycle times—up to 23% faster—and higher material removal rates (MRRs), while conventional milling provided superior dimensional control and smoother surfaces in certain fiber-sensitive regions. A four-tooth cutter with a low helix angle (10°) and aluminum-oxide coating delivered the best overall performance, balancing minimal tool wear with high-quality finishes (arithmetic mean roughness, Ra, as low as 1.36 μm). The results indicate that although conventional milling can exhibit a 25%-lower RMS cutting force, its peak forces and extended machining times may limit the throughput. Conversely, trochoidal milling, when coupled with an appropriately robust tool, effectively manages the cutting forces, improves the surface quality, and reduces the machining time. Most chips produced were less than 11 μm in size, highlighting the need for suitable dust extraction. Notably, a hybrid approach—trochoidal roughing followed by conventional finishing—offers a promising method for achieving both efficient material removal and enhanced dimensional accuracy in GFRP components. Full article

(This article belongs to the Special Issue Research on Metal Cutting, Casting, Forming, and Heat Treatment)

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17 pages, 6327 KiB

Open AccessArticle

Effect of Surface Finishing and Nitriding on the Wetting Properties of Hot Forging Tools

by Jan Kapuściński, Łukasz Macyszyn, Michał Zielinski, Artur Meller, Michał Lehmann and Tomasz Bartkowiak

Materials 2025, 18(1), 172; https://doi.org/10.3390/ma18010172 - 3 Jan 2025

Viewed by 653

Abstract

Lubrication is a critical aspect of the metal forming process and it is strongly influenced by the surface texture of the tool-forming surfaces. This study is focused on determining the effect of surface finish and heat treatment on wettability involving commonly used lubrication agents. Three different finishing states are evaluated (as-ground, as-polished and as-nitrided). Surface topography was measured using a focus variation microscope. Parametric evaluation was carried out according to ISO 25178, including fractal methods. The functional relations between the finish state and wettability, lubricating agent and wettability, selected surface parameters and wettability, as well as between finish state and selected surface parameters, were designated. The results showed that surface finishing treatments, particularly nitriding, influenced both surface roughness and wettability, with varying effects observed across different lubricants and droplet sizes. The findings provide valuable insights into the optimization of lubrication strategies for metal forming processes, highlighting the importance of tailored surface treatments for enhanced tool performance and longevity. Full article

(This article belongs to the Special Issue Research on Metal Cutting, Casting, Forming, and Heat Treatment)

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23 pages, 9802 KiB

Open AccessArticle

Prediction of the Stability of the Casting Process by the HPDC Method on the Basis of Knowledge Obtained by Data Mining Techniques

by Marcin Brzeziński, Jakub Wiśniowski, Mariusz Łucarz, Karolina Kaczmarska, Alena Pribulová and Peter Futáš

Materials 2024, 17(23), 5935; https://doi.org/10.3390/ma17235935 - 4 Dec 2024

Viewed by 1036

Abstract

High-pressure die casting (HPDC) of aluminum alloys is one of the most efficient manufacturing methods, offering high repeatability and the ability to produce highly complex castings. The cast parts are characterized by good surface quality, high dimensional accuracy, and high tensile strength. Continuous technological advancements are driving the increase in part complexity and quality requirements. Numerous parameters impact the quality of a casting in the HPDC process. The most commonly controlled parameters include plunger velocity in the first and second phases, switching point, and intensification pressure. However, a key question arises: is there a parameter that can predict casting quality? This article presents an exploratory analysis of data recorded in a modern HPDC casting machine, focusing on the thickness of the biscuit. The biscuit is the first component of the casting runner system, with a diameter equivalent to that of the injection chamber and a height linked to various processes and mold characteristics. While its diameter is fixed, the thickness varies. The nominal thickness value and tolerances are defined by the process designer based on calculations. Although the thickness of the biscuit does not affect the casting geometry, it influences porosity and cold-shot formation. This study aimed to determine the relationship between biscuit thickness and casting quality parameters, such as porosity. For this purpose, a series of injections was produced using automated gating, and biscuit thicknesses were examined. This article presents quality assessment tools and statistical analyses demonstrating a strong correlation between biscuit thickness and casting quality. The knowledge gained from the methodology and analyses developed in this study can be applied in support systems for the quality diagnostics of HPDC castings. Full article

(This article belongs to the Special Issue Research on Metal Cutting, Casting, Forming, and Heat Treatment)

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19 pages, 8216 KiB

Open AccessArticle

Damage Evolution Mechanism of Railway Wagon Bogie Adapter 1035 Steel and Damage Parameter Calibration Based on Gursone–Tvergaarde–Needleman Model

by Jiachuan Yin, Xiaomin Huang, Guangzhi Ma, Changzhe Song, Xuefeng Tang and Hongchao Ji

Materials 2024, 17(20), 5070; https://doi.org/10.3390/ma17205070 - 17 Oct 2024

Viewed by 960

Abstract

As a critical component of a train, the railway wagon bogie adapter has higher quality requirements. During the forging process, external loads can induce voids, cracks, and other defects in the forging, thereby reducing its service life. Hence, studying the damage behavior of the forging material, specifically AISI 1035 steel, becomes crucial. This study involved obtaining stress–strain curves for AISI 1035 steel through uniaxial tensile tests at temperatures of 900 °C, 1000 °C, and 1100 °C, with strain rates of 0.1 s⁻¹, 1 s⁻¹, and 10 s⁻¹. Subsequently, SEM was used to observe samples at various deformation stages. The damage parameters,

q_{1}

q_{2}

and

q_{3}

in the GTN model “a computational model used to analyze and simulate material damage which can effectively capture the damage behavior of materials under different loading conditions” were then calibrated using the Ramberg–Osgood model and stress–strain curve fitting. Image Pro Plus software v11.1 quantified the sample porosity as

f_{0}

f_{n}

f_{c}

and

f_{F}

. A finite element model was established to simulate the tensile behavior of the AISI 1035 steel samples. By comparing the damage parameters of

f_{0}

f_{n}

f_{c}

and

f_{F}

obtained by the finite element method and experimental method, the validity of the damage parameters obtained by the finite element inverse method could be verified. Full article

(This article belongs to the Special Issue Research on Metal Cutting, Casting, Forming, and Heat Treatment)

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Review

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25 pages, 3754 KiB

Open AccessReview

State of the Art in Incremental Forming: Process Variants, Tooling, Industrial Applications for Complex Part Manufacturing and Sustainability of the Process

by Gabriela-Petruța Popp, Sever-Gabriel Racz, Radu-Eugen Breaz, Valentin Ștefan Oleksik, Mihai-Octavian Popp, Dana-Elena Morar, Anca-Lucia Chicea and Ilie-Octavian Popp

Materials 2024, 17(23), 5811; https://doi.org/10.3390/ma17235811 - 27 Nov 2024

Cited by 3 | Viewed by 1510

Abstract

This paper explores the development and application of the incremental forming process, an innovative method for manufacturing complex parts with high flexibility and low tooling costs. The review categorizes three key process variants: Single Point Incremental Forming (SPIF), Two Point Incremental Forming (TPIF), and Incremental Forming with Conjugated Active Plate (IFCAP). This study demonstrates the significant effects of these process variants on part accuracy and material behavior, particularly under varying process conditions. This study identifies critical technological parameters such as tool diameter, feed rate, and vertical step size. The findings also demonstrate the role of optimized toolpaths and lubrication in improving process efficiency. Applications of incremental forming across various industries, including automotive, aerospace, medical, and construction, demonstrate its versatility in prototype production and small-series manufacturing. These results contribute to a deeper understanding of incremental forming, offering practical recommendations to enhance precision, scalability, and material formability, and supporting future innovations and broader industrial applications. Full article

(This article belongs to the Special Issue Research on Metal Cutting, Casting, Forming, and Heat Treatment)

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