Production and Industrial Engineering in Metal Processing

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 31 August 2025 | Viewed by 3972

Special Issue Editor


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Guest Editor
Department of Mechanical Manufacturing, Faculty of Technology, CEETEPS—State Center of Technological Education “Paula Souza”, Campus Mauá, Av. Antônia Rosa Fioravante 804, Mauá 09390-120, São Paulo, Brazil
Interests: mechanical manufacturing; tribology; abrasive wear; wear test

Special Issue Information

Dear Colleagues,

Extrusion, wire drawing, forging, rolling, plastic forming of metals, turning, milling, drilling, additive manufacturing, welding, and metal casting are all important mechanical and metallurgical manufacturing processes used in the mechanical and metallurgical industries. Studying, researching, and understanding the metallurgical, physical–mechanical, chemical, and tribological factors and behaviours that influence—“positively” or “negatively”—the processing of metallic materials when they are under these metallurgical and mechanical industrial manufacturing processes are important to improve their chemical, metallurgical, mechanical, and tribological performance.

Thus, this Special Issue, titled “Production and Industrial Engineering in Metal Processing”, aims to curate novel advances related to metallurgical and mechanical industrial manufacturing processes, involving the metallurgical and mechanical analysis of metallic materials submitted to plastic forming, machining, and additive manufacturing, in addition to factors related to corrosion, tribological behaviours, as well as the use of modeling and simulation. The topics of interest for this Special Issue include, but are not limited to, the following:

  • Extrusion process;
  • Wire drawing process;
  • Forging process;
  • Rolling process;
  • Plastic deformation of metals—general aspects;
  • Turning process;
  • Milling process;
  • Drilling process;
  • Additive manufacturing;
  • Welding process;
  • Metal casting process;
  • Tribological aspects related to mechanical processes of manufacturing;
  • Industrial lubrication.

Dr. Ronaldo Câmara Cozza
Guest Editor

Manuscript Submission Information

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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. Processes 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 2400 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

  • metallurgical processes of manufacturing
  • mechanical processes of manufacturing
  • plastic deformation of metals
  • machining
  • additive manufacturing
  • wear
  • lubrication

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Published Papers (4 papers)

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Research

33 pages, 5299 KiB  
Article
User Guide and Sensor Selection Guide for Process Transparency
by Sasa Ilic, Patrick Kramer and Michael Marré
Processes 2025, 13(4), 1130; https://doi.org/10.3390/pr13041130 - 9 Apr 2025
Viewed by 285
Abstract
The digital transformation of manufacturing requires an accurate measurement and analysis of process parameters to optimize efficiency, quality and cost control. This paper introduces a structured sensor selection cycle, providing a systematic approach for identifying relevant metrics, evaluating sensor technologies and integrating them [...] Read more.
The digital transformation of manufacturing requires an accurate measurement and analysis of process parameters to optimize efficiency, quality and cost control. This paper introduces a structured sensor selection cycle, providing a systematic approach for identifying relevant metrics, evaluating sensor technologies and integrating them into existing production systems. The proposed methodology enables companies to enhance process transparency, leading to data-driven decision-making and more flexible production strategies. Developed within the ZuPro2Flex research project, this framework offers practical guidance for aligning sensor technology with business model requirements. Full article
(This article belongs to the Special Issue Production and Industrial Engineering in Metal Processing)
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13 pages, 6032 KiB  
Article
Design and Experimental Study of Catenary Linear Horn Based on Ultrasonic Machining
by Liquan Yang, Xuejie Han, Yunfei Xie, Qingqing Lü and Erbo Liu
Processes 2025, 13(3), 714; https://doi.org/10.3390/pr13030714 - 1 Mar 2025
Viewed by 488
Abstract
The amplifier rod, also known as a concentrator, is an important component in ultrasonic transducer devices. Its main functions are amplitude amplification and impedance matching, playing a crucial role in ultrasonic machining systems. This article conducts modal analysis and harmonic response analysis of [...] Read more.
The amplifier rod, also known as a concentrator, is an important component in ultrasonic transducer devices. Its main functions are amplitude amplification and impedance matching, playing a crucial role in ultrasonic machining systems. This article conducts modal analysis and harmonic response analysis of the horn and the tool-added horn, using simulation software, gradually studying the dynamic performance of the catenary linear horn in ultrasonic machining. The optimized frequency of the amplitude rod is obtained, and the effect of the resulting vibration frequency in actual processing is verified through atomization effect tests. The results show that the resonance frequency obtained by finite element analysis has a small error with the actual test, only 0.789%, and magnification error of about 0.165%, which meet the design requirements. It provides reliable design basis and data foundation for the engineering application of the variable rod in ultrasonic machining. Full article
(This article belongs to the Special Issue Production and Industrial Engineering in Metal Processing)
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13 pages, 3165 KiB  
Article
Removal of Primamycin La from Milk Sample Using ZnCl2-Activated Biochar Prepared from Bean Plant as Adsorbent: Kinetic and Equilibrium Calculations
by Muradiye Şahin, Yasin Arslan, Carlos Roberto Luna-Domínguez, Jorge Humberto Luna-Domínguez and Ronaldo Câmara Cozza
Processes 2025, 13(1), 230; https://doi.org/10.3390/pr13010230 - 15 Jan 2025
Viewed by 826
Abstract
In this study, porous biochar (PvBC) was obtained by the pyrolysis of bean (phaseolus vulgaris) plant at 600 °C, and then activated biochar (PvBCZn) was synthesized by ZnCl2 activation at an equal biomass ratio (1.0:1.0). Some analytical techniques (SEM-EDX (scanning [...] Read more.
In this study, porous biochar (PvBC) was obtained by the pyrolysis of bean (phaseolus vulgaris) plant at 600 °C, and then activated biochar (PvBCZn) was synthesized by ZnCl2 activation at an equal biomass ratio (1.0:1.0). Some analytical techniques (SEM-EDX (scanning electron microscopy–energy dispersive X-ray spectroscopy), TGA/DTA (Thermogravimetric/Differential Thermal Analysis), BET (Brunauer–Emmett–Teller), FTIR (Fourier Transform Infrared Spectroscopy) and XRD (X-ray diffraction)) were used to characterize both PvBC and PvBCZn. In addition, their antibiotic sensitivity, water solubility, moisture content and swelling behavior were investigated in detail. Furthermore, both PvBC and PvBCZn were used for the adsorption of primamycin la, an anti-inflammatory drug used in veterinary medicine whose active ingredient is oxytetracycline, in a milk sample. The effect of both pH and adsorbent dosage on the adsorption capacity was investigated. Based on adsorption studies, while the maximum adsorption capacity (qmax) of PvBCZn was found to be 188.48 mg/g, that of PvBC was found to be 122.49 mg/g. According to these results, PvBCZn is an excellent adsorbent for the removal of primamycin la from milk samples. The Langmuir isotherm model and the pseudo-second-order kinetic model were more suitable to describe the adsorption behavior of primamycin la. The PvBCZn adsorbent exhibited rapid removal exceeding 75% in the first 20 min and reached equilibrium after about 50 min. In addition, studies on the desorption and reusability of PvBCZn were carried out under the same optimum experimental conditions. The qmax value of PvBCZn was found to be 171.40 mg/g even in the fifth cycle, confirming the idea that it is a potential adsorbent for the removal of primamycin la. At the same time, the antimicrobial activity of PvBCZn against Escherichia coli bacteria increases its potential to be used in both purification systems and hygiene products. Full article
(This article belongs to the Special Issue Production and Industrial Engineering in Metal Processing)
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17 pages, 1209 KiB  
Article
An Experimental Analysis of Taguchi-Based Gray Relational Analysis, Weighted Gray Relational Analysis, and Data Envelopment Analysis Ranking Method Multi-Criteria Decision-Making Approaches to Multiple-Quality Characteristic Optimization in the CNC Drilling Process
by Fitore Abdullahu, Fatlume Zhujani, Georgi Todorov and Konstantin Kamberov
Processes 2024, 12(6), 1212; https://doi.org/10.3390/pr12061212 - 13 Jun 2024
Cited by 4 | Viewed by 1626
Abstract
The goal of this research is to optimize the input parameters utilized in dry CNC drilling of forging steel to attain sustainable machining. Particular emphasis will be placed on achieving high productivity while minimizing the impact on surface quality. To achieve the aforementioned [...] Read more.
The goal of this research is to optimize the input parameters utilized in dry CNC drilling of forging steel to attain sustainable machining. Particular emphasis will be placed on achieving high productivity while minimizing the impact on surface quality. To achieve the aforementioned goal, three Taguchi-based multi-criteria decision-making (MCDM) approaches, such as traditional gray relational analysis (GRA), weighted gray relational analysis (WGRA), and data envelopment analysis ranking (DEAR), were used for simultaneous optimization of the MRR and Ra. In Taguchi’s L12 (24) orthogonal array design, the cutting mode parameters—such as cutting speed, depth of cut, feed rate, and point angle—have been chosen as the input parameters for the modeling and analysis of the drilling process characteristics. The process of determining the effect of the input parameters on the output parameters was carried out with the use of analysis of variance (ANOVA). The best results from the studies were Ra = 2.19 and MRR = 375 mm3/s, which corresponded to Taguchi’s single optimization levels, S2F1D1A2 and S2F2D2A1, respectively. In the next step, the performance values obtained for each MCDM technique were reoptimized using the Taguchi method, and the optimal levels were obtained: for traditional GRA, the level S2F1D2A1 (Ra = 2.52 µm, MRR = 125 mm3/s); for WGRA, the level S2F1D1A1 (Ra = 2.31 µm, MRR = 83 mm3/s); and for DEAR, the level S2F2D2A1 (Ra = 4.42 µm, MRR = 375 mm3/s), respectively. Lastly, in order to compare the experiments’ performance, validation tests were carried out. The results of the experiments using multi-objective optimization show that traditional GRA improved the overall quality response characteristics by 29.86% compared to the initial setup parameters, while weighted GRA improved them by 34.48%, with the DEAR method providing an improvement of 96%. Based on the findings of this investigation, the DEAR optimization method outperforms the GRA method. As a result, the proposed methods are useful tools for multi-objective optimization of cutting parameters. Full article
(This article belongs to the Special Issue Production and Industrial Engineering in Metal Processing)
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