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Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications

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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 May 2026 | Viewed by 7168

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Dr. Katarzyna Tandecka

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Faculty of Mechanical Engineering and Energy, Koszalin University of Technology, 75-620 Koszalin, Poland
Interests: surface finishing; carbon-based coatings; new parameters for surface assessment; topography; adhesion; micromechanics; additive manufacturing; mechanical properties; 3D spatial scanning; surface metrology; metal machining; metal coatings; nanoparticles; advanced manufacturing; superalloys; surface engineering; tribology
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Dr. Thomas G. Mathia

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Laboratoire de Tribologie et Dynamique des Systemes (LTDS), Ecole Centrale de Lyon, Centre National de la Recherche Scientifique, 69134 Lyon, France
Interests: tribology; rheology; metrology; surface technology; nano-technology; machining; surface characterizations; surface topography; instrumentation design
Special Issues, Collections and Topics in MDPI journals

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Dear Colleagues,

The development of surface topography evaluation, equally with advances in abrasive processing and precision machining technologies, essentially forms part of the backbone of modern manufacturing. This Special Issue will intend to explore recent innovations and research into these important areas. We invite submissions exploring new techniques for measuring surface characteristics, new abrasive materials and techniques, and state-of-the-art manufacturing processes for precision machining. This will include, but is not restricted to, techniques of high-accuracy surface measurement, analyses of abrasive processing, with regard to the surface integrity of work pieces, and machining-parameter optimization for higher performance and durability. In this respect, contributions can highlight how the developed technologies fare with regard to their application within industries such as aerospace, biomedicine, and the automotive industry. This Special Issue will focus on providing an authoritative review of present developments, best practises, and real-world applications that have emanated from the field.

Dr. Katarzyna Tandecka
Dr. Thomas G. Mathia
Guest Editors

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Keywords

surface topography
abrasive processing
precision machining
surface integrity
machining optimization
high-precision measurement
advanced manufacturing technologies

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Related Special Issue

Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications (Second Edition) in Materials

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Research

21 pages, 5289 KB

Open AccessArticle

Surface Topography and Tolerance Quality Evaluation of Polymer Gears Using Non-Contact 3D Scanning Method

by Enis Muratović, Adis J. Muminović, Łukasz Gierz, Ilyas Smailov, Maciej Sydor, Edin Dizdarević, Nedim Pervan and Muamer Delić

Materials 2026, 19(7), 1324; https://doi.org/10.3390/ma19071324 - 26 Mar 2026

Viewed by 120

Abstract

The shift toward lightweight powertrain architectures necessitates a detailed characterization of polymer gears to verify their efficiency and durability. This study investigated the effectiveness of non-contact structured-light 3D scanning for evaluating the surface topography and dimensional tolerance quality of polymer gears produced via distinct manufacturing technologies. A structured-light 3D scanner was used to capture dense point clouds (exceeding 6 million points) of gears produced by three methods: conventional hobbing (POM-C), Material Extrusion (MEX) with carbon fiber reinforcement, and Selective Laser Sintering (SLS). The manufactured parts were compared against the nominal Computer Aided Design (CAD) models to evaluate their geometrical deviations in accordance with DIN 3961 and surface roughness parameters per ISO 25178. The experimental results revealed a consistent ranking of manufacturing quality. The conventionally hobbed POM-C gear exhibited superior precision, achieving DIN quality grades of Q9–Q10 and the smoothest surface finish (S_a = 5.0 µm). Among additive manufacturing techniques, SLS-printed PA 12 showed intermediate quality (Q11, S_a = 12 µm), whereas MEX-printed PPS-CF exhibited significant deviations (exceeding Q12) and the highest surface irregularity (S_a = 25 µm) due to stair-stepping effects. These findings indicate that while additive manufacturing offers geometric flexibility, conventional hobbing retains a decisive advantage in dimensional precision. The optical scanning methodology demonstrated here constitutes an efficient metrological framework for gear quality control, with potential applications extending to the quality assurance of additively manufactured adaptive fixtures and assembly tooling, including automotive assembly operations. Full article

(This article belongs to the Special Issue Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications)

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14 pages, 8191 KB

Open AccessArticle

Surface Topography of Hardened Stainless Steel in Dry Finish Turning Using CBN and Cemented Carbide Inserts

by Kamil Leksycki, Eugene Feldshtein and Jakub Pawłowski

Materials 2026, 19(6), 1103; https://doi.org/10.3390/ma19061103 - 12 Mar 2026

Viewed by 200

Abstract

The proper selection of surface topography (ST) parameters is crucial for ensuring the effective performance of machine components, including their wear and corrosion resistance. In the literature, research on the ST of hardened stainless steels (SSs) after finish turning using cubic boron nitride (CBN) inserts, as well as comparisons with cemented carbide (CC) inserts depending on cutting parameters, is still limited. In this study, the ST of X20Cr13 martensitic hardened SS under dry finish turning with various cutting speeds and feed rates was investigated. Experiments were conducted using a CNC lathe with CBN and CC inserts. A Sensofar S Neox 3D optical profilometer was employed to characterize the ST features, including height surface roughness (SR) parameters, SR profiles, and 2D and 3D surface images. The Parameter Space Investigation method was used to design the experimental plan. For both CBN and CC inserts, the feed rate was the dominant factor influencing the overall SR, described by the Sa and Sq parameters. The extreme parameters Sp, Sv, and Sz were determined by the relationship between feed rate and cutting speed. With appropriately selected turning parameters, it is possible to obtain low Sa values (0.4–0.6 µm), which can eliminate the need for grinding operations. CBN inserts ensured a more regular shape of the ST, while CC inserts contributed to a wavy surface characteristic, associated with more intense plastic deformation. However, low Sa values may be accompanied by isolated peaks, indicating that this parameter does not always fully reflect the presence of extreme micro-irregularities. On the machined surfaces, adhesive bonds of chips and cutting tool material were observed. In addition, micro-scratches were registered for CBN inserts, and a side flow phenomenon for CC inserts. The results confirm that dry turning of hardened SSs can be effectively performed using both CC and CBN inserts. Full article

(This article belongs to the Special Issue Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications)

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14 pages, 3760 KB

Open AccessArticle

Effect of Cutting Conditions on Roughness and Cutting Force When Machining a Freeform Surface with Barrel Tools

by Martin Reznicek, Cyril Horava, Jakub Zajicek and Martin Ovsik

Materials 2026, 19(5), 988; https://doi.org/10.3390/ma19050988 - 4 Mar 2026

Viewed by 280

Abstract

Barrel tools are relatively new tools that use atypical geometries to achieve shorter production times and improve surface quality. They have been increasingly used in the finishing operations industry, where they are gaining more and more popularity. For their optimal use, it is necessary to know how these tools behave during work in terms of how they load the machined product and what surface qualities they can achieve. For this reason, this study was conducted to compare two tools when machining a free surface. The obtained surface quality and the force load caused by the tool were evaluated. It was found that barrel tool machining results in a heterogeneous surface caused by different cutting speeds along the length of the tool and that the two obtained regions show differences in the obtained roughness. Even though the operation was classified as a finishing process, a difference of up to 30% was identified in the cutting forces acting on the tool and the workpiece. Full article

(This article belongs to the Special Issue Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications)

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19 pages, 5275 KB

Open AccessArticle

Prediction of Micro-Milling-Induced Residual Stress and Deformation in Titanium Alloy Thin-Walled Components and Multi-Objective Collaborative Optimization

by Jie Yi, Rui Wang, Dengyun Du, Dong Han, Xinyao Wang and Junfeng Xiang

Materials 2026, 19(2), 219; https://doi.org/10.3390/ma19020219 - 6 Jan 2026

Viewed by 488

Abstract

The intrinsically low stiffness of titanium alloy thin-walled components causes residual stresses to readily accumulate during high-speed micro-milling, leading to deformation and hindering machining precision. To clarify the residual-stress formation mechanism and enable deformation control, this study first proposes a surface residual stress characterization model based on an exponentially decaying sinusoidal function, with model parameters efficiently identified via an improved particle swarm optimization algorithm, allowing rapid characterization of stress distributions under different process conditions. A response surface model constructed using a central composite design is then employed to reveal the coupled effects of machining parameters on residual stress and top-surface deformation. On this basis, a GA-BP neural network–based prediction framework is developed to improve the accuracy of residual stress and deformation prediction, while the AGE-MOEA2 multi-objective evolutionary algorithm is used to optimize micro-milling parameters for the simultaneous minimization of residual stress and deformation via Pareto-optimal solutions. Validation experiments on thin-wall micro-milling confirm that the optimized parameters significantly reduce peak residual stress and suppress top-surface deformation. The proposed modeling and optimization strategy provides an effective reference for high-precision machining of titanium alloy thin-walled components. Full article

(This article belongs to the Special Issue Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications)

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22 pages, 10256 KB

Open AccessArticle

Comparative Study on the Wear Resistance of C&B-Type Polymer Materials for Temporary Crowns Manufactured Using 3D DLP Printing Technology

by Marcel Firlej, Daniel Pieniak, Andrzej Snarski-Adamski, Barbara Biedziak, Agata Niewczas, Jana Petru, Jonas Matijošius, Zbigniew Krzysiak and Katarzyna Zaborowicz

Materials 2025, 18(24), 5478; https://doi.org/10.3390/ma18245478 - 5 Dec 2025

Viewed by 626

Abstract

DLP (Digital Light Processing) 3D printing enables precise fabrication of temporary crowns. Tribological properties of these materials affect clinical durability, wear resistance, and masticatory function. This study compared three C&B-type photopolymers for DLP-printed temporary crowns: Gr-17.1 temporary It, Gr-17 temporary (Pro3dure), and VarseoSmile Temp (BEGO). Samples were printed, post-processed, and polished. Surface topography (Sa, Sz) was measured via white light interferometry, and scratch resistance was evaluated with a Rockwell indenter. Sliding wear tests under wet conditions (37 °C, 90% RH) were conducted using an SRV 4 tester at 25 N for 20,000 cycles. VarseoSmile Temp showed the highest scratch and sliding wear resistance, with the lowest mean volumetric wear (0.025 mm³) and residual scratch depth, reflecting its higher inorganic filler content (30–50 wt%). Gr-17.1 had the most stable coefficient of friction (~0.3), while Gr-17 experienced the greatest wear (0.235 mm³). No direct correlation between friction and wear was observed. These findings indicate that wear resistance depends on microstructure and filler content, supporting tribological testing as a tool to evaluate the durability of 3D-printed temporary crowns. Full article

(This article belongs to the Special Issue Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications)

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17 pages, 6717 KB

Open AccessArticle

Improving the Friction-Wear Properties and Wettability of Titanium Through Microstructural Changes Induced by Laser Surface Treatment

by Agnieszka Twardowska and Łukasz Ślusarczyk

Materials 2025, 18(23), 5410; https://doi.org/10.3390/ma18235410 - 30 Nov 2025

Viewed by 486

Abstract

In this study, a surface treatment of Ti grade 1 was carried out in air with the use of a Yb-fiber laser to increase the friction-wear properties tested in dry contact with α-Al₂O₃. The laser surface treated specimens clearly differ in their surface roughness and wettability, coefficient of friction and resistance to wear, compared to untreated specimens. The microstructure changes induced by laser treatment were investigated using confocal scanning electron microscopy with chemical composition analysis by energy-dispersive spectroscopy, and phase composition by X-ray spectroscopy. It was found that laser surface treatment caused the formation of titanium oxide layers with TiO₂ (rutile, anatase and brookite) as the main constituent, while in the subsurface areas a partial transformation of α-Ti to β-Ti or α′-Ti was thermally induced. Specimens containing β-Ti or α′-Ti in the subsurface area and anatase or brookite in the top layer were characterized by two times lower friction coefficient values and 10 times lower volume wear index Wv in comparison to untreated Ti grade 1. Results clearly confirmed the beneficial effect of laser surface treatment on friction-wear properties of Ti grade 1, but the selection of laser processing parameters was crucial both for resistance to abrasive wear and wettability. Full article

(This article belongs to the Special Issue Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications)

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23 pages, 12603 KB

Open AccessArticle

Application of Laser and Cryogenic Surface Treatment for the Evolution of Surface Morphology in Additively Manufactured Ti-6Al-4V Alloy Samples

by Dorota Laskowska, Monika Szada-Borzyszkowska, Błażej Bałasz, Wiesław Szada-Borzyszkowski and Izabela Bukała

Materials 2025, 18(23), 5315; https://doi.org/10.3390/ma18235315 - 25 Nov 2025

Viewed by 509

Abstract

This study investigates the effects of laser and cryogenic (dry ice) surface treatments on enhancing surface characteristics of Ti-6Al-4V titanium alloy components produced using the Selective Laser Melting (SLM) technique. Components produced via additive manufacturing often exhibit increased surface irregularities and residual unmelted powder, which can deteriorate their mechanical strength and resistance to corrosion. In this study, SLM samples manufactured with two laser powers (176 W and 220 W) were subjected to laser cleaning and dry ice blasting under various process parameters. Surface topography and morphology analyses were performed. The obtained results showed that both methods improved surface uniformity and removed contaminants. Dry ice treatment effectively removed loose powder particles and impurities without causing structural changes—the best results were obtained at a pressure of 10 bar. Laser treatment, depending on the focal length, produced varying degrees of surface remelting—from gentle smoothing (500 mm) to intensive thermal effects and microcracks (250 mm). The research confirmed that cryogenic cleaning is an environmentally friendly and safe post-processing method, while laser cleaning enables deeper surface structure modification, requiring further optimization. Full article

(This article belongs to the Special Issue Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications)

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20 pages, 5992 KB

Open AccessArticle

Analysis of Thick-Walled Oxygen-Free Copper Pipe Production in the Bridge Die Extrusion Process

by Marcin Knapiński, Grzegorz Banaszek, Anna Kawałek, Teresa Bajor and Grzegorz Boczkal

Materials 2025, 18(23), 5304; https://doi.org/10.3390/ma18235304 - 25 Nov 2025

Viewed by 506

Abstract

This article presents the results of research on the possibility of extruding oxygen-free copper pipes in bridge dies. The possibility of continuous production of a finished product of any length with a uniformly deformed wall was analysed. One of the most important elements of the work was to determine the shape of the tool (die and bridge) that would allow durable connection of the material. Numerical studies conducted using the commercial computer programme FORGE^®NxT 2.1, including analysis of the distribution of material temperature and hydrostatic pressure in the welding zone of the bridge die affecting the copper joint during the manufacture of tubular profiles, confirmed the validity of the research issue. The results of the numerical studies were supplemented by laboratory tests, confirming the accuracy of the selected variant of the finished product manufacturing process. The process of bonding under conditions of two-part material compression was used for physical modelling of copper welding. The tests were conducted using the Gleeble 3800 metallurgical process simulator with the PocketJaw module. Based on the analysis of the obtained results, it was found that for tubes with a wall-thickness-to-inner-diameter ratio of 0.5, it is justified to use tools with a longer sizing section and welding chamber, as well as a larger mandrel generating-line angle within the welding chamber. Full article

(This article belongs to the Special Issue Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications)

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25 pages, 13857 KB

Open AccessArticle

Unit Load of Abrasive Grains in the Machining Zone During Microfinishing with Abrasive Films

by Katarzyna Tandecka, Wojciech Kacalak, Filip Szafraniec and Thomas G. Mathia

Materials 2024, 17(24), 6305; https://doi.org/10.3390/ma17246305 - 23 Dec 2024

Cited by 2 | Viewed by 1558

Abstract

This work investigates the contact between abrasive particles and workpieces in microfinishing processes with special consideration given to the determination of unit force, unit pressure, and grain, the forces exerted by individual abrasive grains. A detailed methodology was established for measuring the contact area, penetration depth, and circumferences of grain imprints at depths corresponding to multiples of the total height of the abrasive film, represented by the parameter Sz. The following depths were analyzed: 0.05 Sz, 0.15 Sz, 0.25 Sz, and 0.35 Sz. Results show that the areas closer to the central microfinishing zone bear the highest unit pressures and forces and, thus, contribute dominantly to material removal. It was further found that near the edges of the contact zone, the pressure and force have been reduced to lower material removal efficiency. The non-uniform geometry of abrasive particles was found to significantly affect contact mechanics, more at shallow depths of penetration, whereas the shape of the apex defines the nature of the interaction. A parabolic force and pressure distribution were evident for the irregular load distribution of the microfinishing area. The result brings out the need for further refinement in the design of the abrasive film and pressure distribution in order to achieve improvement in uniformity and efficiency during microfinishing. It would bring out valuable insights on how to improve the effectiveness of an abrasive film and ways of optimizing the process conditions. The results provide a founding stone for further advancement of knowledge in the grain–workpiece interaction, enabling better surface quality and more reliable microfinishing processes. Full article

(This article belongs to the Special Issue Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications)

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19 pages, 24669 KB

Open AccessArticle

Investigation of the Thermophysical Simulation and Material Removal Mechanism of the High-Volume-Fraction SiCp/Al Composite in Wire Electrical Discharge Machining

by Zhi Chen, Jiawen Hu, Hongbing Zhou, Yumeng Wei, Guojun Zhang and Fenglin Han

Materials 2024, 17(22), 5546; https://doi.org/10.3390/ma17225546 - 13 Nov 2024

Cited by 4 | Viewed by 1160

Abstract

SiC particle reinforced aluminum matrix composites (SiCp/Al) are widely used in aviation, weaponry, and automobiles because of their excellent service performance. Wire electrical discharge machining (WEDM) regardless of workpiece hardness has become an alternative method for processing SiCp/Al composites. In this paper, the temperature distribution and the discharge crater size of the SiCp/Al composite are simulated by a thermophysical model during a single-pulse discharge process (SPDP) based on the random distribution of SiC particles. The material removal mechanism of the SiCp/Al composite during the multi-pulse discharge process (MPDP) is revealed, and the surface roughness (Ra) of the SiCp/Al composite is predicted during the MPDP. The thermophysical model simulation results during the MPDP and experimental characterization data indicate that the removal mechanism of SiCp/Al composite material consists of the melting and vaporization of the aluminum matrix, as well as the heat decomposition and shedding of silicon carbide particles. Pulse-on time (T_on), pulse-off time (T_off), and servo voltage (SV) have a great influence on surface roughness. The Ra increases with an increase in T_on and SV, but decreases slightly with an increase in T_off. Moreover, compared with experimental data, the relative error of Ra calculated from the thermophysical model is 0.47–7.54%. This means that the developed thermophysical model has a good application and promotion value for the WEDM of metal matrix composite material. Full article

(This article belongs to the Special Issue Evaluation of the Surface Topography, Abrasive Processing, and Precision Machining Technology and Applications)

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