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Advanced Materials Machining: Theory and Experiment

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

Deadline for manuscript submissions: 10 December 2025 | Viewed by 594

Special Issue Editors


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Guest Editor
Department of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, 35-959 Rzeszow, Poland
Interests: machining; grinding; cutting tools; grinding wheels; cutting process diagnostics
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Guest Editor
Department of Manufacturing and Materials Engineering, Faculty of Mechanical Engineering, Opole University of Technology, 45-271 Opole, Poland
Interests: manufacturing technologies; theory and modelling of machining processes; computed tomography; surface metrology; materials science; reverse engineering; robotization of manufacturing processes
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
Faculty of Manufacturing Technologies of the Technical University of Košice with the Seat in Prešov, Bayerova 1, 080 01 Prešov, Slovakia
Interests: advanced manufacturing technologies; water jetting; hybrid technologies

Special Issue Information

Dear Colleagues,

The machining of modern materials, such as titanium and nickel alloys, composites, and advanced ceramics, presents numerous challenges due to their high hardness, wear resistance, and low thermal conductivity. Consequently, machining these materials is associated with rapid tool wear, the necessity for precise cooling systems, and the selection of machining parameters and strategies to ensure the required workpiece quality. Furthermore, the demands for process efficiency and sustainability drive the need to optimize machining technologies, including the use of advanced tools with coatings, as well as technologies such as High-Speed Machining (HSM), High-Feed Milling (HFM), and Minimum Quantity Lubrication (MQL) cooling.

This Special Issue is dedicated to research on modern material machining technologies, aiming to deepen understanding of processes and phenomena and improve the efficiency and reliability of existing machining methods. The scope of this Special Issue includes studies on cutting tools, particularly their geometry and wear; the modeling and simulation of machining processes with an emphasis on numerical methods and artificial intelligence; and investigations into cutting parameters and strategies, cooling methods, quality parameters after machining (such as surface roughness, waviness, dimensional and shape accuracy), and the condition of the surface layer.

Dr. Łukasz Żyłka
Prof. Krzysztof Żak
Prof. Dr. Sergej Hloch
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

  • precision machining
  • machining and machinability
  • difficult-to-cut materials
  • metals and alloys
  • cutting process modelling and optimization
  • machining simulation
  • tool wear and durability
  • surface topography
  • diagnostics and process monitoring
  • cooling conditions

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Published Papers (1 paper)

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Research

22 pages, 10596 KiB  
Article
Detection of Defects in Solid Carbide Cutting Tools During Creep-Feed Flute Grinding (CFG) Using Recurrence Analysis
by Marcin Sałata, Robert Babiarz and Krzysztof Kęcik
Materials 2025, 18(12), 2743; https://doi.org/10.3390/ma18122743 - 11 Jun 2025
Viewed by 343
Abstract
This study presents a comprehensive analysis of defect detection in the manufacturing process of solid carbide milling tools. The creep-feed flute grinding technique was used to fabricate a milling tool, with cutting force signals recorded and examined using recurrence analysis and conventional statistical [...] Read more.
This study presents a comprehensive analysis of defect detection in the manufacturing process of solid carbide milling tools. The creep-feed flute grinding technique was used to fabricate a milling tool, with cutting force signals recorded and examined using recurrence analysis and conventional statistical methods. The analysis identified four distinct dynamic fluctuations (cutting force amplitude jumps), which showed a direct correlation with the formation of microcracks on the flute surface. These jumps exhibited varying levels of reduction, ranging from 5% to 22% in amplitude. A detailed investigation, including recurrence plots and recurrence quantification analysis (RQA) with a moving-window approach, revealed that several recurrence indicators, such as the recurrence rate (RR), determinism (DET), and maximum diagonal line length (LMAX), were highly effective in detecting microcracks, as their values significantly deviated from the reference level. These results were compared with conventional statistical analysis, and interestingly, the recurrence methods demonstrated greater sensitivity, successfully detecting additional very small cutting force jumps that conventional statistical methods could not identify. Full article
(This article belongs to the Special Issue Advanced Materials Machining: Theory and Experiment)
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