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Metals
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Advanced Precision Machining of Metallic Surfaces
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Advanced Precision Machining of Metallic Surfaces

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: closed (31 August 2023) | Viewed by 6220

Special Issue Editor

Dr. Ramanuj Kumar

E-Mail Website
Guest Editor
Machining Research Laboratory (MRL), School of Mechanical Engineering, Kalinga Institute of Industrial Technology (KIIT), Deemed to be University, Bhubaneswar 751024, Odisha, India
Interests: hardened steel, hard turning; superalloys, high temperature alloys, Titanium alloys, machining; minimum quantity lubrication; nanofluid; cryogenic cooling; tool condition monitoring; hybrid machining; electro discharge machining; FEM simulation; optimization; modelling, tribology

Special Issue Information

Dear Colleagues,

Advanced precision machining is a field that encompasses many technologies that have been applied as science has evolved. These developments enable the production of parts with increasing precision in a shorter time. It is based on the use of advanced computerized machine tools that achieve high tolerances and create complex geometric cuts with high repeatability and accuracy. High-precision machining is in great demand in aerospace, medical and automotive-components-making industries to avoid any premature failure during their service life. Nowadays, many advanced precision machining techniques have evolved to achieve the desired goal of manufacturing. Currently, ultra-precision machining is emerging as an advanced precision machining technique, which typically includes ultra-precision diamond turning, ultra-precision diamond milling, ultra-precision diamond scratching, ultra-precision grinding and ultra-precision polishing. This has been established as a very capable solution to the machinist to achieve nano-scale finishing with sub-micron tolerance. Moreover, micro-machining, laser-assisted machining, high-speed machining and hard turning also provide  high tolerance and superior surface quality.

In this Special Issue, we welcome articles that focus on advance precision machining techniques such as ultra-precision machining, micro-machining, laser-assisted machining, high-speed machining, hard machining, and any other novel machining techniques. Additionally, articles on surface roughness, surface integrity, machined surface characterization, advanced algorithms, simulations, adaptive control and machine learning techniques to enable precision machining are welcomed. 

Dr. Ramanuj Kumar
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

  • ultra-precision machining
  • micro-machining
  • laser-assisted machining
  • high-speed machining
  • hard machining
  • surface charectrization
  • precision manufacturing
  • precision metrology
  • advanced materials
  • optimization
  • modeling

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Published Papers (2 papers)

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Research

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24 pages, 6210 KiB  
Article
Machinability Comparison of TiCN-Al2O3-TiN, TiAlN-TiN, and TiAlSiN Coated Carbide Inserts in Turning Hardened AISI 4340 Steel Using Grey-Crow Search Hybrid Optimization
by Mohammed Al Awadh, Ramanuj Kumar, Oğur İynen, Mohammad Rafighi, Mustafa Özdemir and Anish Pandey
Metals 2023, 13(5), 973; https://doi.org/10.3390/met13050973 - 17 May 2023
Cited by 2 | Viewed by 2438
Abstract
This experimental study presents the machinability comparison of TiCN-Al2O3-TiN, TiAlN-TiN, and TiAlSiN coated carbide inserts in hard turning AISI 4340 steel. The primary purpose of this research is to determine the most appropriate cutting inserts in turning hardened AISI [...] Read more.
This experimental study presents the machinability comparison of TiCN-Al2O3-TiN, TiAlN-TiN, and TiAlSiN coated carbide inserts in hard turning AISI 4340 steel. The primary purpose of this research is to determine the most appropriate cutting inserts in turning hardened AISI 4340 (30–40 HRC) steel considering surface roughness (Ra), cutting sound (Cs), power consumption (P), radial force (Fx), tangential force (Fy), and feed force (Fz). To fulfill this objective, the turning experiments for each tool were executed based on the Taguchi L9 design. The comparative assessment of cutting tools revealed that the TiAlSiN coated tool exhibited superior performance compared to other tools. Machining with the TiCN-Al2O3-TiN coated tool showed 32.05% greater roughness than with the TiAlN-TiN coated tool, and 68.80% higher surface roughness than the TiAlSiN coated tool. The main novelty of this research is considering the cutting sound and power consumption as responses to select the most suitable cutting tools. Moreover, a novel grey-crow search hybrid was executed to perceive the optimal value of the input parameters. The optimal local value of cutting speed for the TiAlSiN coated tool was found to be 220 m/min, while for the TiCN-Al2O3-TiN and TiAlN-TiN tools, it was the same as 182 m/min. Considering the optimum cutting parameters, the material removal rate for TiCN-Al2O3-TiN, TiAlN-TiN, and TiAlSiN was found to be 639.9 mm3/min, 606.4 mm3/min, and 761.2 mm3/min, respectively. Thus, the TiAlSiN coated tool has greater MRR capability in comparison to other tools. Therefore, this leads to the conclusion that the TiAlSiN tool may be the better choice in comparison to other selected tools for turning hardened steels. Full article
(This article belongs to the Special Issue Advanced Precision Machining of Metallic Surfaces)
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Review

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18 pages, 55926 KiB  
Review
Manufacturing Methods Induced Property Variations in Ti6Al4V Using High-Speed Machining and Additive Manufacturing (AM)
by Shivam Pradeep Yadav and Raju S. Pawade
Metals 2023, 13(2), 287; https://doi.org/10.3390/met13020287 - 31 Jan 2023
Cited by 12 | Viewed by 3115
Abstract
Additive manufacturing techniques are replacing conventional subtractive machining processes; however, the surface quality and defects have been a key roadblock to expanding AM’s uses. This paper describes experimental investigations in the high-speed dry machining and additive manufacturing (AM) of titanium alloy (Ti6Al4V), discussing [...] Read more.
Additive manufacturing techniques are replacing conventional subtractive machining processes; however, the surface quality and defects have been a key roadblock to expanding AM’s uses. This paper describes experimental investigations in the high-speed dry machining and additive manufacturing (AM) of titanium alloy (Ti6Al4V), discussing the effect of machining and AM conditions on the surface characteristics due to the micro-deformation layer. Analysis of the machined surfaces shows the deposition of microparticles at a high cutting speed of 170 m/min at moderate feed rates. The predominant thermal softening effect at a high cutting speed causes restructuring of the micro-deformation layer. Thus, the machined surface shows fewer alterations and a correspondingly lower surface roughness. A high cutting speed also favors the induction of high residual stresses that are compressive. Shallow grooves are seen throughout the surface along the feed spacing with a higher depth of cut of 0.8 mm. An increase in the cutting speed from 170 m/min to 190 m/min leads to a 61% increase in the surface finish owing to a rise in machining temperature leading to thermal softening, and subsequent restructuring of the machined surface layer occurs. For the feed rate, the surface finish values decrease gradually as the feed rate increases, and the worst finish of 1.37 µm is attained at a feed rate of 0.875 mm/rev. This study also compares different AM processes for Ti6Al4V based on the defects and their effects on mechanical properties, such as tensile and fatigue strength. It was observed that the ultimate tensile strength and the yield strength were approximately 20% more in SLM and direct energy deposition as compared to electron beam melting. The mechanism of these effects is also explained by elaborating on the influence of grain size, phase, and other microstructural behaviors on the final mechanical properties of the produced part. Full article
(This article belongs to the Special Issue Advanced Precision Machining of Metallic Surfaces)
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