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Metals
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Green Hybrid Machining Technology for Difficult-Machining Metal Materials
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Green Hybrid Machining Technology for Difficult-Machining Metal Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: 20 May 2025 | Viewed by 6739

Special Issue Editor

Dr. Jinfu Zhao

E-Mail Website
Guest Editor
School of Mechanical Engineering, Shandong University, Jinan 250061, China
Interests: coating; cutting; heat transfer; temperature monitoring
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleague,

Difficult-to-machine metal materials exhibit excellent material properties and could effectively ensure the functional and structural integrity of product components under extreme service conditions. Green hybrid machining technologies provide novel solutions for the high-quality and high-efficiency machining of difficult-to-machine materials with environmentally friendly benefits. It is crucial to clarify the machining mechanism and related machining rules of surface integrity for the industrial application of green hybrid machining technology.

This Special Issue aims to solicit research/review papers on novel green or/and hybrid machining technology for difficult-to-machine metal materials in scientific research or industry.

Dr. Jinfu Zhao
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 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. Metals is an international peer-reviewed open access monthly 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

  • hybrid machining technology
  • green machining technology
  • ultrasonic vibration-assisted machining
  • laser-assisted machining
  • difficult-to-machine materials
  • high-temperature alloy
  • composite material
  • hard and brittle material
  • machining surface integrity
  • material removal mechanism

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Published Papers (5 papers)

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Research

25 pages, 15227 KiB  
Article
Mechanism of Multi-Physical Fields Coupling in Macro-Area Processing via Laser–Electrochemical Hybrid Machining (LECM)
by Guangxian Li, Zhikun Su, Tingan Zhao, Wei Wei and Songlin Ding
Metals 2024, 14(12), 1390; https://doi.org/10.3390/met14121390 - 4 Dec 2024
Cited by 1 | Viewed by 926
Abstract
Laser–electrochemical hybrid machining (LECM) is promising in the processing of thin-wall parts, which avoids problems such as the weak stiffness of structures and thermal defects. However, while most studies focus on precision machining via LECM, few investigate the potential of this technique in [...] Read more.
Laser–electrochemical hybrid machining (LECM) is promising in the processing of thin-wall parts, which avoids problems such as the weak stiffness of structures and thermal defects. However, while most studies focus on precision machining via LECM, few investigate the potential of this technique in macro-area processing. In this paper, the synergistic effects on the coupling of thermal field and electrochemical field on bulk material removal mechanisms in the LECM of additively manufactured Ti6Al4V are comprehensively analyzed experimentally and theoretically. According to the experimental results, LECM improved the material removal rate (MRR) by up to 28.6% compared to ECM. The induction of the laser increases local heating, accelerating the temperature rise of the electrolyte, eventually promoting the electrochemical reaction. The hydrogen bubble flow promotes overall heat convection between the electrode and workpiece, which facilitates the removal of the facial precipitates and increases the efficiency of electrochemical dissolution. Higher voltages and laser powers promote the formation of hydrogen bubble flow; meanwhile, they also aggravate laser energy scattering, limiting the overall machining efficiency. Additionally, laser irradiation causes the ablation and rupture of hydrogen bubbles, which weakens the bubble flow effect and ultimately decreases the material removal efficiency. This study reveals the underlying mechanisms of the joint effects of the laser field and electrical field in LECM, and the findings can provide valuable insights for the optimization of LECM parameters in industrial applications. Full article
(This article belongs to the Special Issue Green Hybrid Machining Technology for Difficult-Machining Metal Materials)
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12 pages, 6535 KiB  
Article
Study on the Surface Quality of Overhanging Holes Fabricated by Additive/Subtractive Hybrid Manufacturing for Ti6Al4V Alloy
by Yanmei Liu, Weijian Liu, Yingwei Zhang, Feng Guan, Xiong Xue, Yongsheng Zheng and Qian Bai
Metals 2024, 14(9), 979; https://doi.org/10.3390/met14090979 - 28 Aug 2024
Viewed by 821
Abstract
Additive/subtractive hybrid manufacturing (ASHM) based on laser powder bed fusion (LPBF) enables to achieve high precision and good surface quality of complex structures such as small holes with overhanging features. However, the rapid heating and cooling rates during the ASHM results in sinkage [...] Read more.
Additive/subtractive hybrid manufacturing (ASHM) based on laser powder bed fusion (LPBF) enables to achieve high precision and good surface quality of complex structures such as small holes with overhanging features. However, the rapid heating and cooling rates during the ASHM results in sinkage at the alternating interface of additive manufacturing and subtractive milling, which degrades the surface quality of the components. This study employs shielding height at the alternating interface to solve this problem and improve the surface quality. The effect of internal diameters and shielding heights on the surface quality were studied experimentally for overhanging holes fabricated by ASHM of Ti6Al4V. The results show that the Ti6Al4V samples prepared by LPBF possessed high density and uniformly distributed microstructure. For overhanging holes without shielding height, the largest depth value of sinkage and surface roughness were obtained, indicating a worse surface quality; when the shielding height was increased to 0.5 mm, the smallest sinkage value and surface roughness were obtained, indicating a better surface quality. With the same shielding height, the overhanging holes with different diameters had a similar surface roughness. This study reveals that an appropriate shielding height can improve the surface quality, which provides guidance to the improvement of the surface quality for complex structures in ASHM. Full article
(This article belongs to the Special Issue Green Hybrid Machining Technology for Difficult-Machining Metal Materials)
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19 pages, 5354 KiB  
Article
Rapid Assessment of Steel Machinability through Spark Analysis and Data-Mining Techniques
by Goran Munđar, Miha Kovačič, Miran Brezočnik, Krzysztof Stępień and Uroš Župerl
Metals 2024, 14(8), 955; https://doi.org/10.3390/met14080955 - 22 Aug 2024
Cited by 1 | Viewed by 1373
Abstract
The machinability of steel is a crucial factor in manufacturing, influencing tool life, cutting forces, surface finish, and production costs. Traditional machinability assessments are labor-intensive and costly. This study presents a novel methodology to rapidly determine steel machinability using spark testing and convolutional [...] Read more.
The machinability of steel is a crucial factor in manufacturing, influencing tool life, cutting forces, surface finish, and production costs. Traditional machinability assessments are labor-intensive and costly. This study presents a novel methodology to rapidly determine steel machinability using spark testing and convolutional neural networks (CNNs). We evaluated 45 steel samples, including various low-alloy and high-alloy steels, with most samples being calcium steels known for their superior machinability. Grinding experiments were conducted using a CNC machine with a ceramic grinding wheel under controlled conditions to ensure a constant cutting force. Spark images captured during grinding were analyzed using CNN models with the ResNet18 architecture to predict V15 values, which were measured using the standard ISO 3685 test. Our results demonstrate that the created prediction models achieved a mean absolute percentage error (MAPE) of 12.88%. While some samples exhibited high MAPE values, the method overall provided accurate machinability predictions. Compared to the standard ISO test, which takes several hours to complete, our method is significantly faster, taking only a few minutes. This study highlights the potential for a cost-effective and time-efficient alternative testing method, thereby supporting improved manufacturing processes. Full article
(This article belongs to the Special Issue Green Hybrid Machining Technology for Difficult-Machining Metal Materials)
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15 pages, 12138 KiB  
Article
Effects of TiAlN Coating Thickness on Machined Surface Roughness, Surface Residual Stresses, and Fatigue Life in Turning Inconel 718
by Aisheng Jiang, Jinfu Zhao, Pengcheng Cui, Zhanqiang Liu and Bing Wang
Metals 2024, 14(8), 940; https://doi.org/10.3390/met14080940 - 17 Aug 2024
Cited by 2 | Viewed by 1347
Abstract
The surface roughness and surface residual stresses are affected by the coating thickness of physical vapor deposition (PVD) TiAlN tools, which could alter the service performance of machined components. However, the relationships among the tool coating thickness, the machined surface roughness, the surface [...] Read more.
The surface roughness and surface residual stresses are affected by the coating thickness of physical vapor deposition (PVD) TiAlN tools, which could alter the service performance of machined components. However, the relationships among the tool coating thickness, the machined surface roughness, the surface residual stress, and the fatigue life are still not sufficiently illustrated. In this research, PVD TiAlN coatings with several thicknesses of 1.6 μm, 2 μm, 2.5 μm, and 3 μm were deposited on carbide tools. Turning experiments using Inconel 718 were conducted with uncoated and various TiAlN tools under flood cooling conditions. The surface roughness could be improved with the selection of thin PVD TiAlN coating thicknesses of 1.6 μm and 2 μm compared to that of uncoated tools. The tensile residual stresses at the machined surface in the directions of cutting speed and feed rate linearly decreased by 148.67% and exponentially decreased by 92.24% when the TiAlN coating thickness was increased from 0 μm to 3 μm. The values of the low-cycle fatigue life of machined Inconel 718 linearly increased by 15.60% with the increase in TiAlN coating thickness from 0 μm to 3 μm, which was mainly due to the improvement of surface residual stresses. The results could provide guidance for the selection of suitable TiAlN coating thicknesses for wet machining Inconel 718 based on the part service conditions. Full article
(This article belongs to the Special Issue Green Hybrid Machining Technology for Difficult-Machining Metal Materials)
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18 pages, 18967 KiB  
Article
Numerical Study on Fretting Wear of DZ125/FGH99 Tenon/Mortise Joint Structure
by Laicong Song, Zhenyu Shi, Chengpeng Zhang and Yong Li
Metals 2024, 14(7), 830; https://doi.org/10.3390/met14070830 - 19 Jul 2024
Viewed by 1636
Abstract
Fretting wear in the contact area between the aero-engine blade tenon and turbine disk mortise has an important influence on the performance of the aero-engine. In this paper, the tenon joint structure of the DZ125/FGH99 superalloy material is taken as the research object, [...] Read more.
Fretting wear in the contact area between the aero-engine blade tenon and turbine disk mortise has an important influence on the performance of the aero-engine. In this paper, the tenon joint structure of the DZ125/FGH99 superalloy material is taken as the research object, and the finite element model of the fir-tree tenon joint structure is established. Through subroutine invocation and mesh adaptive control technology, the fretting wear problem of dissimilar material contact pairs under composite load is numerically studied. The results show that for the specific tenon joint structure and load and boundary conditions studied in this paper, the maximum wear occurs on the contact surface of the first tooth, and the surface will show different partial slip states in different load cycles. The slip region always extends from the two contact edges to the interior, and the upper side has a larger range. Wear has a significant effect on the stress distribution and stick–slip state of the contact surface. The second and third teeth have a small amount of wear and are basically in a stick state during the entire wear process. Therefore, wear has little effect on the stress distribution and the stick–slip state of the contact surface. This study reveals the coupling relationship between the fretting wear and contact state of the tenon joint structure. Full article
(This article belongs to the Special Issue Green Hybrid Machining Technology for Difficult-Machining Metal Materials)
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