Special Issue "Optimization and Simulation in Alloy Cutting Processes"

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

Deadline for manuscript submissions: 30 December 2020.

Special Issue Editor

Prof. Wojciech Zębala
E-Mail Website
Guest Editor
Politechnika Krakowska, Krakow, Poland
Interests: production engineering;construction and operation of machines; physical aspects of the cutting process; precision machining; cutting of difficult-to-cut materials; modeling and simulation of machining processes; numerical calculation methods (FEM);CNC machine tools; CAD/CAM systems; measurements of the geometric surface structure and modern manufacturing techniques (HSC, HPC, Hard machining,3D printing).

Special Issue Information

Dear Colleagues,

In the last few years, we have observed rapid development in the automation of manufacturing processes, especially in automatic control systems. Progress in cutting stimulates a significant increase in the metal removal rate and achievement of high dimensional and shape accuracy of machine parts. To meet today’s high demands concerning the accuracy and efficiency of the manufacturing, it is necessary to use computer methods for the design and optimization of technological processes. The construction of machining simulation models allows, for example, fast visualization of the chip formation process in a wide range of machining parameters.

Machining operations can be applied to metallic (mainly alloys) and non-metallic materials like ceramics, composites, polymer, and wood. New materials, which play a key role, are used to produce cutting tools. The aim of all work related to the chip-forming simulation research is, first of all, to specify the material model characterizing the physical properties of the tool and workpiece materials, the friction model between the chip and tool, and to describe the shape of the tool, and which geometry of the rake face significant influences on the formed chip.

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 of 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 for this Special Issue.

Prof. Wojciech Zębala
Guest Editor

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 papers will be 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 2000 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
  • Simulation of cutting processes
  • Optimization of manufacturing
  • Physical phenomena during cutting
  • Material models
  • Difficult-to-cut materials

Published Papers (7 papers)

Order results
Result details
Select all
Export citation of selected articles as:

Research

Open AccessArticle
Optimization of Cutting Data and Tool Inclination Angles During Hard Milling with CBN Tools, Based on Force Predictions and Surface Roughness Measurements
Materials 2020, 13(5), 1109; https://doi.org/10.3390/ma13051109 - 02 Mar 2020
Abstract
This work deals with technological considerations required to optimize the cutting data and tool path pattern for finishing the milling of free-form surfaces made of steel in a hardened state. In terms of technological considerations, factors such as feed rate, workpiece geometry, tool [...] Read more.
This work deals with technological considerations required to optimize the cutting data and tool path pattern for finishing the milling of free-form surfaces made of steel in a hardened state. In terms of technological considerations, factors such as feed rate, workpiece geometry, tool inclination angles (lead and tilt angles) and surface roughness are taken into account. The proposed method is based on calculations of the cutting force components and surface roughness measurements. A case study presented in the paper is based on the AISI H13 steel, with hardness 50 HRC and milling with a cubic boron nitride (CBN) tool. The results of the research showed that by modifications of the feed value based on the currently machined cross-sectional area, it is possible to control the cutting force components and surface roughness. During the process optimization, the 9% and 15% increase in the machining process efficiency and the required surface roughness were obtained according to the tool inclination angle and feed rate optimization procedure, respectively. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
Show Figures

Figure 1

Open AccessArticle
Analysis of the Machinability of Copper Alloy Ampcoloy by WEDM
Materials 2020, 13(4), 893; https://doi.org/10.3390/ma13040893 - 17 Feb 2020
Abstract
The unconventional technology of wire electrical discharge machining is widely used in all areas of industry. For this reason, there is always an effort for efficient machining at the lowest possible cost. For this purpose, the following comprehensive study has been carried out [...] Read more.
The unconventional technology of wire electrical discharge machining is widely used in all areas of industry. For this reason, there is always an effort for efficient machining at the lowest possible cost. For this purpose, the following comprehensive study has been carried out to optimize the machining of the copper alloy Ampcoloy 35, which is particularly useful in plastic injection moulds. Within the study, a half-factor experiment of 25-1 with 10 axial points and seven central points of a total of 33 rounds was carried out, which was focused on the response monitoring of the input factors in the form of the machine parameters setup: gap voltage, pulse on time, pulse off time, discharge current, and wire speed. Based on the study of the response in the form of cutting speed and surface topography, their statistical models were created, while the optimal setting of machine parameters was determined to maximize the cutting speed and minimize the topography parameters. Further, a detailed cross-sectional analysis of surface and subsurface layer morphology was performed using electron microscopy including chemical composition analysis. In order to study microstructural changes in the material at the atomic level, a lamella was created, which was then studied using a transmission electron microscope. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
Show Figures

Figure 1

Open AccessArticle
Optimization and Modeling of Process Parameters in Multi-Hole Simultaneous Drilling Using Taguchi Method and Fuzzy Logic Approach
Materials 2020, 13(3), 680; https://doi.org/10.3390/ma13030680 - 03 Feb 2020
Cited by 1
Abstract
In industries such as aerospace and automotive, drilling many holes is commonly required to assemble different structures where machined holes need to comply with tight geometric tolerances. Multi-spindle drilling using a poly-drill head is an industrial hole-making approach that allows drilling several holes [...] Read more.
In industries such as aerospace and automotive, drilling many holes is commonly required to assemble different structures where machined holes need to comply with tight geometric tolerances. Multi-spindle drilling using a poly-drill head is an industrial hole-making approach that allows drilling several holes simultaneously. Optimizing process parameters also improves machining processes. This work focuses on the optimization of drilling parameters and two drilling processes—namely, one-shot drilling and multi-hole drilling—using the Taguchi method. Analysis of variance and regression analysis was implemented to indicate the significance of drilling parameters and their impact on the measured responses i.e., surface roughness and hole size. From the Taguchi optimization, optimal drilling parameters were found to occur at a low cutting speed and feed rate using a poly-drill head. Furthermore, a fuzzy logic approach was employed to predict the surface roughness and hole size. It was found that the fuzzy measured values were in good agreement with the experimental values; therefore, the developed models can be effectively used to predict the surface roughness and hole size in multi-hole drilling. Moreover, confirmation tests were performed to validate that the Taguchi optimized levels and fuzzy developed models effectively represent the surface roughness and hole size. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
Show Figures

Figure 1

Open AccessArticle
The Effect of the Feed Direction on the Micro- and Macro Accuracy of 3D Ball-end Milling of Chromium-Molybdenum Alloy Steel
Materials 2019, 12(24), 4038; https://doi.org/10.3390/ma12244038 - 04 Dec 2019
Abstract
The machining of free form surfaces is one of the most challenging problems in the field of metal cutting technology. The produced part and machining process should satisfy the working, accuracy, and financial requirements. The accuracy can describe dimensional, geometrical, and surface roughness [...] Read more.
The machining of free form surfaces is one of the most challenging problems in the field of metal cutting technology. The produced part and machining process should satisfy the working, accuracy, and financial requirements. The accuracy can describe dimensional, geometrical, and surface roughness parameters. In the current article, three of them are investigated in the case of the ball-end milling of a convex and concave cylindrical surface form 42CrMo4 steel alloy. The effect of the tool path direction is investigated and the other cutting parameters are constant. The surface roughness and the geometric error are measured by contact methods. Based on the results, the surface roughness, dimensional error, and the geometrical error mean different aspects of the accuracy, but they are not independent from each other. The investigated input parameters have a similar effect on them. The regression analyses result a very good liner regression for geometric errors and shows the importance of surface roughness. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
Show Figures

Figure 1

Open AccessArticle
Impact of Process Parameters on the Quality of Deep Holes Drilled in Inconel 718 Using EDD
Materials 2019, 12(14), 2298; https://doi.org/10.3390/ma12142298 - 18 Jul 2019
Cited by 1
Abstract
Advanced engineering materials (e.g., nickel or titanium alloy) are being increasingly applied to produce parts of gas turbines in the aerospace industry. To improve the durability of these parts, many holes, with a length-to-diameter aspect ratio greater than 20:1, are created in their [...] Read more.
Advanced engineering materials (e.g., nickel or titanium alloy) are being increasingly applied to produce parts of gas turbines in the aerospace industry. To improve the durability of these parts, many holes, with a length-to-diameter aspect ratio greater than 20:1, are created in their structure. The quality of the holes significantly affects the cooling process of the elements. However, it is challenging to machine materials by conventional methods. When machining a hole with a high aspect ratio, the major problem is effective flushing of the machining area, which can improve the hole’s surface integrity and dimensional accuracy. Consequently, the electro-discharge drilling (EDD) process is good alternative for this application. This paper presents the results of an analysis of the EDD of Inconel 718 alloy. An experiment was conducted to evaluate the impact of process parameters (pulse time, current amplitude, and discharge voltage) on the process’s performance (linear tool wear, taper angle, drilling speed, the hole’s aspect ratio, and surface roughness (Ra and Rz)). The results show that EDD provides us with the possibility to drill holes with an aspect ratio greater than 10:1. The results also demonstrate that holes with an aspect ratio greater than 10:1 and a small taper angle value have a significantly decreased quality of internal surface, especially at the bottom of the hole. This indicates that an insufficient amount of debris is removed from the bottom of the hole. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
Show Figures

Figure 1

Open AccessArticle
A Methodology to Systematically Investigate the Diffusion Degradation of Cemented Carbide during Machining of a Titanium Alloy
Materials 2019, 12(14), 2271; https://doi.org/10.3390/ma12142271 - 15 Jul 2019
Cited by 4
Abstract
Using Ti6Al4V as a work material, a methodology to systematically investigate the diffusion degradation of cemented carbide during machining is proposed. The methodology includes surface characterization of as-tested worn inserts, wet etched worn inserts, metallographic cross-sectioned worn inserts as well as the back-side [...] Read more.
Using Ti6Al4V as a work material, a methodology to systematically investigate the diffusion degradation of cemented carbide during machining is proposed. The methodology includes surface characterization of as-tested worn inserts, wet etched worn inserts, metallographic cross-sectioned worn inserts as well as the back-side of the produced chips. Characterization techniques used include scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), Auger electron spectroscopy (AES) and time of flight secondary ion mass spectroscopy (ToF-SIMS). The results show that the characterization of wet etched worn inserts gives quick and useful information regarding the diffusion degradation of cemented carbide, in the present work the formation of a fine crystalline W layer (carbon depleted WC layer) at the tool-work material interface. The present study also illuminates the potential of AES analysis when it comes to analyzing the degradation of cemented carbide in contact with the work material during machining. The high surface sensitivity in combination with high lateral resolution makes it possible to analyze the worn cemented carbide surface on a sub-µm level. Especially AES sputter depth profiling, resulting in detailed information of variations in chemical composition across interfaces, is a powerful tool when it comes to understanding diffusion wear. Finally, the present work illustrates the importance of analyzing not only the worn tool but also the produced chips. An accurate characterization of the back-side of the chips will give important information regarding the wear mechanisms taking place at the tool rake face–chip interface. Surface analysis techniques such as AES and ToF-SIMS are well suited for this type of surface characterization. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
Show Figures

Figure 1

Open AccessArticle
Study on ASJ Cutting of TC18, Based upon Multivariate Nonlinear Regression and SA-BP-AGA
Materials 2019, 12(12), 1902; https://doi.org/10.3390/ma12121902 - 13 Jun 2019
Abstract
TC18 titanium alloy has been widely applied, but is considered as a difficult machining material. Taking the kerf angle as the quality criterion, this paper studied the cutting performance of TC18 by the use of an abrasive slurry jet (ASJ), based upon multivariate [...] Read more.
TC18 titanium alloy has been widely applied, but is considered as a difficult machining material. Taking the kerf angle as the quality criterion, this paper studied the cutting performance of TC18 by the use of an abrasive slurry jet (ASJ), based upon multivariate nonlinear regression and SA-BP-AGA. Cutting experiments were carried out according to the Taguchi orthogonal method. The experimental factors included traverse speed, standoff distance, pressure and slurry concentration, with five levels set, respectively. Meanwhile, a characterization method of the major influencing factors was proposed. A multiple nonlinear regression model and a back propagation artificial neural network (BP) prediction model, based on adaptive genetic algorithm (AGA), were established. The reliability was verified by statistics equations for the 22 groups of the fitting or training model and the three groups of experimental results. The BP-AGA and Simulated annealing algorithm (SA) were used to form a set of prediction optimization systems, called integrated SA-BP-AGA. Finally, the results showed that the main factor influencing the kerf angle is the slurry concentration. BP-AGA is easier to model, offers better robustness and is more accurate than a multivariate nonlinear regression model. The best kerf angle can be predicted by the integration system. The study results can improve the performance for the machining of TC18 by ASJ. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
Show Figures

Figure 1

Back to TopTop