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High-Efficiency Machining of Conventional and Unconventional Metal Materials

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

Deadline for manuscript submissions: 20 January 2026 | Viewed by 662

Special Issue Editors


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Guest Editor
Institute of Mechanical Engineering, University of Zielona Gora, 4 Prof. Z. Szafrana Street, 65-516 Zielona Gora, Poland
Interests: machining of hard-to-cut materials, e.g., stainless steel, titanium and its alloys; physical phenomena of the cutting process; shaping the geometric structure of the materials surface; friction and wear behavior of materials; cooling and lubrication conditions during machining
Special Issues, Collections and Topics in MDPI journals

E-Mail Website
Guest Editor
Institute of Mechanical Engineering, University of Zielona Gora, 4 Prof. Z. Szafrana street, 65-516 Zielona Gora, Poland
Interests: machining of hard-to-cut and unconventional materials, e.g., stainless steels, titanium alloys, powder metallurgy materials; physical phenomena of the cutting process; shaping the material surface texture; wear behavior of cutting tools; friction and wear behavior of the aforementioned materials and coatings; cooling and lubrication conditions during machining; plasma and laser processing conditions
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Today, metallic materials, both conventional and unconventional, are widely used in many branches of industry, including the medical, aerospace, automotive, marine, and defense fields.

The wide range of applications for these material groups requires the use of both conventional steels and metal alloys (stainless steels, titanium alloys, cobalt alloys, nickel alloys, nickel–chromium superalloys, etc.) in addition to unconventional materials such as ceramics, composites, multilayer structures, and others.

While the characteristics of conventional materials are well known, the main advantages of unconventional materials include their attractive structural, mechanical, and thermal properties, as well as others, which in turn implies the use of technologies such as high-temperature thermo-mechanical machining, powder metallurgy, plasma or laser coating, and additive manufacturing technologies.

On the other hand, it is necessary to ensure the high productivity and quality of production processes, which is an extremely difficult task, since the aforementioned materials are considered difficult to cut.

The main objectives and directions of this Special Issue are to describe the latest advancements in the following:

  • Details of chip shaping in cutting;
  • The influence of cutting and abrasive machining conditions on the basic process characteristics;
  • Contemporary issues of cutting tool and abrasive tool operating;
  • The use of effective technological media, such as minimum cooling and lubrication, high-pressure lubrication, etc..;
  • The impact of cutting and abrasive machining conditions on surface integrity features;
  • Finish machining of additive manufacturing products;
  • Development of high-performance cutting (HPC), high-speed cutting (HSC), high-speed grinding (HSG), and so on.

Dr. Kamil Leksycki
Prof. Dr. Eugene Feldshtein
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

  • high-efficiency machining
  • cutting
  • abrasive machining
  • surface texture
  • additive manufacturing

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Published Papers (2 papers)

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Research

23 pages, 11844 KB  
Article
Comparison of Approaches to Determining the Coefficient of Friction in Stretch-Forming Conditions
by Tomasz Trzepieciński, Krzysztof Szwajka, Valmir Dias Luiz, Joanna Zielińska-Szwajka and Marek Szewczyk
Materials 2025, 18(19), 4534; https://doi.org/10.3390/ma18194534 - 29 Sep 2025
Abstract
Control of the friction process in stretch-forming conditions, when creating sheet metal, is essential for obtaining components of the quality required. This paper presents an approach to modelling the friction phenomenon at the rounded edges of stamping dies. The aim of the study [...] Read more.
Control of the friction process in stretch-forming conditions, when creating sheet metal, is essential for obtaining components of the quality required. This paper presents an approach to modelling the friction phenomenon at the rounded edges of stamping dies. The aim of the study is to compare the coefficient of friction (CoF) determined from numerous analytical models available in the literature. Experimental studies were conducted using self-developed bending under tension friction testing apparatus. The test material was low-carbon DC01 steel sheeting. Tests were conducted under lubricated conditions, using industrial oil intended for deep drawing operations. The surfaces of countersamples made of 145Cr6 substrate were modified using the ion implantation of Pb (IOPb) and electron beam melting processes. Variation in the CoF in BUT tests was related to continuous deformation-induced changes in surface topography and changes in the mechanical properties of sheet metal due to the work-hardening phenomenon. Under friction testing with a stationary countersample, the largest increase in average roughness (by 19%) was found for the DC01/IOPb friction pair. The friction process caused a significant decrease in kurtosis values. The results show that the difference between the highest and lowest CoF values, determined for the analytical models considered, was approximately 40%. Full article
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21 pages, 7064 KB  
Article
Challenges in Temperature Measurement in Hot Forging Processes: Impact of Measurement Method Selection on Accuracy and Errors in the Context of Tool Life and Forging Quality
by Marek Hawryluk, Łukasz Dudkiewicz, Jakub Krawczyk, Marta Janik, Marzena Lachowicz and Mateusz Skwarski
Materials 2025, 18(16), 3850; https://doi.org/10.3390/ma18163850 - 17 Aug 2025
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Abstract
This study investigates the influence of temperature measurement accuracy on tool failure mechanisms in industrial hot forging processes. Challenges related to extreme operational conditions, including high temperatures, limited access to measurement surfaces, and optical interferences, significantly hinder reliable data acquisition. Thermal imaging, pyrometry, [...] Read more.
This study investigates the influence of temperature measurement accuracy on tool failure mechanisms in industrial hot forging processes. Challenges related to extreme operational conditions, including high temperatures, limited access to measurement surfaces, and optical interferences, significantly hinder reliable data acquisition. Thermal imaging, pyrometry, thermocouples, and finite element modeling were employed to characterize temperature distributions in forging tools and billets. Analysis of multi-stage forging of stainless steel valve forgings revealed significant discrepancies between induction heater settings and actual billet surface temperatures, measured by thermal imaging. This thermal non-uniformity led to localized underheating and insufficient dissolution of hard inclusions, confirmed by dilatometric tests, resulting in billet jamming and premature tool failure. In slender bolt-type forgings, excessive or improperly controlled billet temperatures increased adhesion between the forging and tool surface, causing process resistance, billet sticking, and accelerated tool degradation. Additional challenges were noted in tool preheating, where non-uniform heating and inaccurate temperature assessment compromised early tool performance. Measurement errors associated with thermal imaging, particularly due to thermal reflections in robotic gripper monitoring, led to overestimated temperatures and overheating of gripping elements, impairing forging manipulation accuracy. The results emphasize that effective temperature measurement management, including cross-validation of methods, is crucial for assessing tool condition, enhancing process reliability, and preventing premature failures in hot forging operations. Full article
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