Optimization and Simulation in Alloy Cutting Processes (Third Edition)

Dear Colleagues,

Modern machining processes increasingly rely on automation and advanced simulation tools to improve productivity, process stability, and dimensional accuracy. Finite element method (FEM)-based software packages, such as DEFORM, Abaqus, and AdvantEdge, enable comprehensive modeling of key phenomena in cutting operations, including chip formation mechanisms, thermal effects, stress distribution, and tool wear progression. These tools significantly reduce the need for costly physical trials and support the optimal selection of machining parameters.

A growing area of interest is the machining of components produced by additive manufacturing (AM) technologies such as SLM, EBM, and FDM. Materials like Ti6Al4V, Inconel 718, and 316L stainless steel manufactured via AM often exhibit unique microstructural characteristics, including anisotropic grain structures, internal porosity, high hardness gradients, and residual stresses. These features can negatively influence machinability by increasing cutting forces, accelerating tool wear, and complicating chip control.

FEM-based simulation is, therefore, essential not only for predicting material behavior during post-processing but also for tailoring machining strategies in order to improve surface integrity and overall process efficiency. Such simulations support the integration of AM with subtractive methods in hybrid manufacturing workflows.

This Special Issue aims to present recent advances in the optimization of cutting processes for modern manufacturing engineering, especially CNC machining, application of modern tools for machining difficult-to-cut materials, modeling and computer simulation of machining, and analysis of physical phenomena existing in the decohesion zone of the machined material.

It is my pleasure to invite you to submit original, high-quality research papers, short communications, and state-of-the-art reviews to this Special Issue.

We look forward to receiving your contributions.

Prof. Dr. Wojciech Zębala
Guest Editor

Dr. Emilia Franczyk
Guest Editor Assistant

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