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Manufacturing Technology, Materials and Methods (Second Edition)
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Manufacturing Technology, Materials and Methods (Second Edition)

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

Deadline for manuscript submissions: closed (10 April 2025) | Viewed by 10639

Special Issue Editors

Dr. Rafał Gołębski

E-Mail Website
Guest Editor
Faculty of Mechanical Engineering and Computer Science, Department of Technology and Automation, Częstochowa University of Technology, 42-201 Czestochowa, Poland
Interests: manufacturing technology; machining; CNC machine tools; gears technology
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Antun Stoić

E-Mail Website
Guest Editor
Mechanical Engineering Faculty, University of Slavonski Brod, 35000 Slavonski Brod, Croatia
Interests: machining technologies; machine tools; process monitoring; cutting tools and accessories, machinability
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Manufacturing technologies are used in many fields. They are used to achieve production sustainability and cost-effective product manufacturing. The processes, materials, and technologies used, as well as their impact, are important features of the entire production chain.

This Special Issue of Materials deals with analyses applied using various manufacturing technologies, studies of the phenomena accompanying manufacturing processes, as well the use of engineering tools.

Your contributions could help us to understand and solve the challenges currently facing experts and researchers. Manuscripts should be related to the machining of metals and alloys, cold metal processing, welding, production and analysis of polymers and composites, issues related to the research of tools and tooling systems, surface engineering, coordinate measuring, reverse engineering, and accompanying phenomena manufacturing processes, such as friction and wear.

It is our pleasure to invite you to submit a manuscript to this Special Issue of Materials. Articles, reviews, and communications are also all welcome.

Dr. Rafał Gołębski
Prof. Dr. Antun Stoić
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

  • machining of metals and alloys
  • cold metal processing
  • polymers and composites processing
  • welding
  • tools and tooling systems
  • surface engineering
  • coordinate measuring
  • wear and friction
  • reverse engineering

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Related Special Issue

Published Papers (7 papers)

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Research

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21 pages, 13392 KiB  
Article
Impact of Chip Breaker Geometry on the Performance of Actively Rotary Monolithic Turning Tools
by Richard Joch, Miroslav Cedzo, Andrej Czán, Michal Šajgalík, Jozef Holubják, Mário Drbúl, Jaromír Markovič and Miroslav Matuš
Materials 2025, 18(5), 1154; https://doi.org/10.3390/ma18051154 - 4 Mar 2025
Viewed by 749
Abstract
The control of chip formation is a key aspect of modern turning operations, as improper chip formation can negatively affect tool life, surface quality, and overall machining efficiency. One approach to improving chip control is the integration of a chip breaker into the [...] Read more.
The control of chip formation is a key aspect of modern turning operations, as improper chip formation can negatively affect tool life, surface quality, and overall machining efficiency. One approach to improving chip control is the integration of a chip breaker into the geometry of the cutting tool. This study examines the impact of chip-breaking geometry on the performance of monolithic rotary tools in active rotation turning. Two types of tools were compared: one without a chip breaker and another with an integrated chip breaker. The functionality of the chip breaker was experimentally validated, demonstrating its effectiveness in shaping chip segmentation under specific process parameters. Furthermore, tool wear, workpiece surface roughness, and cutting forces were evaluated. The findings indicate that the tool equipped with a chip breaker exhibits reduced wear while maintaining comparable surface quality. However, this benefit is accompanied by a slight increase in cutting forces. Full article
(This article belongs to the Special Issue Manufacturing Technology, Materials and Methods (Second Edition))
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14 pages, 4533 KiB  
Article
Application of Cold Plasma to Reduce the Roughness of the Working Surface of a Railway Car Center Plate
by Maryna Bulakh
Materials 2024, 17(22), 5437; https://doi.org/10.3390/ma17225437 - 7 Nov 2024
Viewed by 734
Abstract
This paper presents a study on the use of cold plasma to reduce the roughness of the working surface of center plates of railway cars. The use of cold plasma is a promising method of surface treatment which allows for a significant reduction [...] Read more.
This paper presents a study on the use of cold plasma to reduce the roughness of the working surface of center plates of railway cars. The use of cold plasma is a promising method of surface treatment which allows for a significant reduction in roughness without changing the mechanical and chemical properties of the material. As part of the study, experiments were conducted on the treatment of center plates with cold plasma, the surface roughness was measured before and after the treatment, and the microhardness, microstructure, and chemical composition of the material were analyzed. The results of our experimental studies show that the use of cold plasma can reduce roughness by 1.4–1.6 times. At the same time, the roughness parameters Ra are reduced by 29.1–37.4%, and Rz by 29.3–39.6%. A slight increase of 2.81–3.31% in the roughness parameter Sa is also obtained after cold plasma treatment compared to the base samples. Thus, the use of cold plasma for the treatment of center plates of railway cars can significantly increase their durability and reduce the costs of manufacture or repair, making this method promising for use in the railway industry. Full article
(This article belongs to the Special Issue Manufacturing Technology, Materials and Methods (Second Edition))
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18 pages, 3532 KiB  
Article
The Dynamic Comprehensive Evaluation of the Importance of Cutting Parameters in the Side Milling TC4 Process Using an Integrated End Mill
by Xingfu Zhao, Yanzhong Wang, Lin Jin, Zemin Zhao, Daxun Yue, Yuyuan Wang, Zengcheng Wang and Zongxu Dai
Materials 2024, 17(11), 2744; https://doi.org/10.3390/ma17112744 - 4 Jun 2024
Cited by 1 | Viewed by 965
Abstract
In the cutting process, there are many parameters that affect the cutting effect, and the same parameter has different degrees of influence on different performance indicators, which makes it difficult to select key parameters for parameter optimization and parameter combination evaluation while considering [...] Read more.
In the cutting process, there are many parameters that affect the cutting effect, and the same parameter has different degrees of influence on different performance indicators, which makes it difficult to select key parameters for parameter optimization and parameter combination evaluation while considering multiple performance indicators at the same time. The process of titanium alloy milling with an integrated end mill is studied herein. The values of cutting tool flank face wear and material removal rates are obtained with experimental and analytical methods. Numerical characteristics and causes of the cutting tool flank face wear at different stages are also analyzed. The dynamic, comprehensive evaluation method based on the double incentives model is used to evaluate the dynamic, comprehensive importance of cutting parameters in view of the problem of considering multiple performance indicators and the characteristics of the dynamic change in performance indicators in the cutting process. According to the result of a dynamic, comprehensive evaluation, the cutting parameters with the highest comprehensive importance are selected. Finally, the radar map is used to plot the comprehensive importance of the cutting parameters. The overall comprehensive importance of each cutting parameter is intuitively displayed as well. As a result of the research, the dynamic, comprehensive evaluation method based on the double incentives model has a good application value in the evaluation of tool performance in the cutting process and can quickly select the best tool performance parameter combination; it is established that the most comprehensive parameter is the cutting speed, and the cutting width is the second most important. In turn, the comprehensive importance of the cutting depth is the lowest. Full article
(This article belongs to the Special Issue Manufacturing Technology, Materials and Methods (Second Edition))
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14 pages, 2832 KiB  
Article
Quality Evaluation of New Types of Layered Composites for Flooring Materials
by Sylwia Olenska and Piotr Beer
Materials 2024, 17(8), 1892; https://doi.org/10.3390/ma17081892 - 19 Apr 2024
Cited by 1 | Viewed by 953
Abstract
The need, or even the obligation, to take care of the natural environment compels a search for new technological solutions, or for known solutions to be adapted to new applications. The maxim is ‘don’t harm, but improve the world for future generations’. In [...] Read more.
The need, or even the obligation, to take care of the natural environment compels a search for new technological solutions, or for known solutions to be adapted to new applications. The maxim is ‘don’t harm, but improve the world for future generations’. In the wood industry in particular, given that it is based on a natural raw material, we must look for ecological solutions. Trees grow, but the demand for wood exceeds the volume of tree growth. In industrial manufacturing, one of the ways to make full use of wood is through chipless processing, which occurs during rotary cutting (peeling). In addition, wood is a natural material, each fragment of which has a range of properties. In addition, wood defects in quality manipulation generate a lot of waste. The aim of this study was to analyse the quality effect of the tested layered composites for flooring materials on production application. The practical purpose was to exchange actual sawing-based production for chipless production. The composite base layers were made of pine wood (Pinus L.) veneers with differing quality classes. The samples were subjected to three-point bending tests to calculate the moduli of elasticity and stiffness, which are the most important parameters. Because both analysed parameters describe product quality, the analyses were based on the creation of Shewhart control charts for each parameter. In theory, these control charts are tools for analysing whether the production process is stable and yields predictable results. To have full control over the process, five elements have to be applied: central line (target), two types of control lines (upper and lower) and two types of specification lines (upper and lower). New types of layered composites for flooring may be applied to production once verified using Shewhart control charts. It turns out that it is possible to produce the base layer of the flooring materials using the rotary cutting (peeling) method without having to analyse the quality of the raw material. This is a way to significantly increase the efficiency of production in every element of manufacturing. Full article
(This article belongs to the Special Issue Manufacturing Technology, Materials and Methods (Second Edition))
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16 pages, 3270 KiB  
Article
Lifetime Analysis of Dies Manufactured by Conventional Processes and Reconditioned by Deposition Welding Operation
by Daniela Maria Iovanas and Adela-Eliza Dumitrascu
Materials 2024, 17(7), 1469; https://doi.org/10.3390/ma17071469 - 22 Mar 2024
Cited by 1 | Viewed by 1047
Abstract
The refurbishment of dies by the deposition welding of wear areas is an efficient and economical process. The aim of this study was to conduct a comparative analysis of the lifetimes of different types of dies for the manufacturing of wagon wheels. The [...] Read more.
The refurbishment of dies by the deposition welding of wear areas is an efficient and economical process. The aim of this study was to conduct a comparative analysis of the lifetimes of different types of dies for the manufacturing of wagon wheels. The analyzed dies were manufactured by conventional processes (Type I) and reconditioned through a deposition welding procedure using a dedicated electrode (Type II). The Anderson–Darling test was conducted to analyze the goodness of fit of the lifetime data specific to the die types. The maximum likelihood estimation method (MLE) with a 95% confidence interval (CI) was applied in order to estimate the lifetime distribution parameters. It was found that the lifetimes of type II dies were longer than those of type I dies. The mean time to failure (MTTF) recorded for reconditioned dies was 426 min, while the mean time to failure of dies manufactured by conventional processes was approximatively 253 min. In addition, an accentuated hazard rate for type I dies compared to type II dies was observed. The results of this analysis emphasized the fact that dies can be restored to their initial operating capacity by successfully using deposition welding procedures that confer a high resistance to operational loads. At the same time, the use of these procedures allows for the sustainable development of resources and waste management. Full article
(This article belongs to the Special Issue Manufacturing Technology, Materials and Methods (Second Edition))
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19 pages, 25860 KiB  
Article
Selected Properties of the Surface Layer of C45 Steel Samples after Slide Burnishing
by Agnieszka Skoczylas and Mariusz Kłonica
Materials 2023, 16(19), 6513; https://doi.org/10.3390/ma16196513 - 30 Sep 2023
Cited by 9 | Viewed by 1745
Abstract
This paper presents the experimental results of a study investigating the impact of the machining fluid type, the variable factor, used in slide burnishing on 2D and 3D surface roughness; surface topography; Abbott–Firestone curve shape; microhardness; and SFE (surface free energy). In the [...] Read more.
This paper presents the experimental results of a study investigating the impact of the machining fluid type, the variable factor, used in slide burnishing on 2D and 3D surface roughness; surface topography; Abbott–Firestone curve shape; microhardness; and SFE (surface free energy). In the experiment, pre-ground, ringed samples of C45 steel were used. The results showed an over eight-fold decrease in the value of the Ra (arithmetical mean deviation) parameter and over a five-fold decrease in the Rt (total height of profile) parameter in relation to their values after grinding. The parameters Rpk (reduced peak height), Rk (core roughness depth), and Rvk (reduced valley depth) were also reduced. The Abbott–Firestone curve after slide burnishing changed its angle of inclination (it was more flattened), and the material ratio Smr increased. The reduction in the Rpk and Rk parameters and increased material ratio will most likely contribute to restoring the functionality of these surfaces (increased resistance to abrasive wear). After slide burnishing, the maximum 25% increase in microhardness was obtained compared to the value after grinding, while the layer thickness was 20 μm. The surface energy of elements subjected to slide burnishing using various machining fluids slightly increased, or its value was close to that of the ground surface. The most favourable properties of the surface layer in terms of mating between two elements were obtained for a part that was slide-burnished with a mixture of oil + polymethyl methacrylate (PMM) + molybdenum disulphide (MoS2). Full article
(This article belongs to the Special Issue Manufacturing Technology, Materials and Methods (Second Edition))
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Review

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23 pages, 14535 KiB  
Review
Technological Aspects of Manufacturing and Control of Gears—Review
by Piotr Boral, Rafał Gołębski and Ruzena Kralikova
Materials 2023, 16(23), 7453; https://doi.org/10.3390/ma16237453 - 30 Nov 2023
Cited by 7 | Viewed by 3392
Abstract
Gear drives are widely used in various fields and applications due to their properties and capacity. Their versatility, durability, and ability to transmit high torques as well as precision and reliability make them extremely useful in many fields of technology. They are widely [...] Read more.
Gear drives are widely used in various fields and applications due to their properties and capacity. Their versatility, durability, and ability to transmit high torques as well as precision and reliability make them extremely useful in many fields of technology. They are widely used in industrial and energy machinery, vehicle drive systems, aerospace, medical devices, and many other areas. Gears can be manufactured using many technologies. This work focuses mainly on machining with particular emphasis on high-performance new technologies. The process of mathematical modeling of the gear and the machined profile is strongly related to CNC machining technologies. A robust correlation of systems supporting the design and modeling of sliding gears needed for the manufacturing process is presented in the article. It is very important to properly assess gears with correct manufacturing in accordance with a specific standard. The article presents an analysis of available methods for controlling gears using coordinate measurement techniques. Gear machining methods were assessed in terms of the technologies used as well as their productivity and manufacturing tolerance. Full article
(This article belongs to the Special Issue Manufacturing Technology, Materials and Methods (Second Edition))
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