Special Issue "New Frontiers in Magnetic Polishing and Electrochemical Technology"

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

Deadline for manuscript submissions: 30 April 2022.

Special Issue Editors

Prof. Dr. A-Cheng Wang
E-Mail Website
Guest Editor
Department of Mechanical Engineering, Chien Hsin University of Science and Technology, Taoyuan 320, Taiwan
Interests: 1. Magnetic abrasive finishing: this research includes equipment designs, abrasive characteristics, machining methods and control algorithms; 2. Abrasive flow machining: this research includes equipment and fixture designs, abrasive characteristics, machining methods and control algorithms; 3. Micro hole polishing: this research includes equipment and fixture designs, polishing method developments; 4. Electrical discharge machining: this research includes lateral electrode designs, helical electrode design and machining process, dielectric characteristics in EDM
Prof. Dr. Jung-Chou Hung
E-Mail Website
Guest Editor
Department of Mechanical Engineering, National Central University, Taoyuan 32001, Taiwan
Interests: electrochemical machining (ECM); electrical discharge machining (EDM); ultrasonic machining (USM); micromachining; array and batch processing; mold design and multiple physical simulation analysis for ECM; metal surface treatment, R&D of insulating materials; superalloy machining; non-conductor hard and brittle material processing; computer-integrated intelligent manufacturing

Special Issue Information

Dear Colleagues,

Some important components, such as turbine blades, hydraulic valves, inject nozzles, cooling channels, etc., provide beneficial properties—high mechanical strength, high temperature withstanding ability and good wear resistance—to apply in the precision industry; however, these components are not easy to make using traditional methods. Electrochemical technology and magnetic polishing are nontraditional means that can manufacture or finish these elements effectively by discharge erosion, electrolysis or magnetic abrasive polish. The above technologies can create self-sharpening, self-adaptability and self-controllability capabilities to remove material, deteriorated layers or micro cracks from workpieces and easily obtain precise and complex elements.

In recent years, many kinds of magnetic polishing and electrochemical technology have been developed via machining equipment, cutting tools and control methods in order to obtain high quality products, therefore, equipment functions, tool characteristics and control algorithms have likewise been widely studied in the past few decades. Moreover, machine learning in these technologies has also been investigated extensively due to great improvement in equipment performance and mass production of precision elements, especially micro elements and fine structures, which are easily made by the wisdom learning system.

This Special Issue welcomes novel processing research submissions, such as miniaturization, precision, composite, intelligent, multiple physical coupling, simulation analysis, difficult-to-machine appearance and inner hole feature processing, new material processing technology, etc. We hope that experts and scholars can contribute their research to this Special Issue. Thanks a lot.

Prof. Dr. A-Cheng Wang
Prof. Dr. Jung-Chou Hung
Guest Editors

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. 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 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

  • magnetic abrasive polishing
  • electrochemical technology
  • abrasive
  • machine learning
  • electrolysis
  • electrical discharge machining
  • laser machining
  • electromagnetic effects

Published Papers (5 papers)

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Research

Article
Optimal Selection of Backside Roughing Parameters of High-Value Components Using Abrasive Jet Processing
Processes 2021, 9(9), 1661; https://doi.org/10.3390/pr9091661 - 14 Sep 2021
Viewed by 417
Abstract
This paper mainly presents a set of new Sapphire Backside Roughing technology. Presently, the associated Sapphire Backside Roughing technology is still concentrated on chemical etching, as its yield rate and efficiency are often limited by lattice structures, and the derived chemical waste fluid [...] Read more.
This paper mainly presents a set of new Sapphire Backside Roughing technology. Presently, the associated Sapphire Backside Roughing technology is still concentrated on chemical etching, as its yield rate and efficiency are often limited by lattice structures, and the derived chemical waste fluid after etching is most likely to cause ecological contamination. In this research, refined abrasive jet processing technology is adopted, and in the meantime, the Taguchi experiment design method is taken for detailed experimental planning. Through processing parameter conditions and abrasive selection and development, proper surface roughing and processing uniformity are obtained so as to improve the various weak points of the abovementioned traditional etching effectively. It is discovered that abrasive blasting processing technology is, respectively, combined with wax-coated #1000 SiC particles and wax-coated #800 Zirconium particles to process the sapphire substrate with initial surface roughness 0.8–0.9 μmRa from the experiment. A 1.1–1.2 μmRa surface roughness effect can be achieved about two minutes later. The experimental results show that the actual degree of sapphire substrate surface roughing obtained in the AJM process depends on the gas pressure, impact angle, wax-coated abrasives, and additives. The new Sapphire Backside Roughing technology has high flexibility, which not only meets the requirements for sapphire surface roughing specification but can also effectively reduce the sapphire substrate roughing time and related cost. Full article
(This article belongs to the Special Issue New Frontiers in Magnetic Polishing and Electrochemical Technology)
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Article
Multi-Performance Optimization in Electrical Discharge Machining of Al2O3 Ceramics Using Taguchi Base AHP Weighted TOPSIS Method
Processes 2021, 9(9), 1647; https://doi.org/10.3390/pr9091647 - 13 Sep 2021
Viewed by 248
Abstract
The main application of electrical discharge machining in ceramic processing is limited to conductive ceramics. However, the most commonly used non-conductive potteries in modern industry, such as aluminum oxide (Al2O3), also reveal the limitations of choosing a suitable process. [...] Read more.
The main application of electrical discharge machining in ceramic processing is limited to conductive ceramics. However, the most commonly used non-conductive potteries in modern industry, such as aluminum oxide (Al2O3), also reveal the limitations of choosing a suitable process. In this study, Taguchi based TOPSIS coupled with AHP weight method to optimize the machining parameters of EDM on Al2O3 leads to better multi-performance. The results showed that the technique is suitable for tackling multi-performance machining parameter optimization. The adhesive foil had a significant impact on material removal rate, electrode wear rate, and surface roughness, according to the findings. In addition, the response graph of relative closeness is used to determine the optimal combination levels of machining parameters. A confirmation test revealed a good agreement between predicted and experimental preference values at an optimum combination of the input parameters. The suggested experimental and statistical technique is a simple, practical, and reliable methodology for optimizing EDM process parameters on Al2O3 ceramics. This approach might be utilized to optimize and improve additional process parameters in the future. Full article
(This article belongs to the Special Issue New Frontiers in Magnetic Polishing and Electrochemical Technology)
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Article
An Investigation of Ultrasonic-Assisted Electrochemical Machining of Micro-Hole Array
Processes 2021, 9(9), 1615; https://doi.org/10.3390/pr9091615 - 08 Sep 2021
Viewed by 263
Abstract
This paper uses an ultrasonic vibration-integrated array electrode for 301 stainless steel micro-hole drilling. The influence of machining parameters such as ultrasonic vibration amplitude, working voltage, pulse-off time and electrode feed rate on different processing characteristics are discussed. The experimental results show that [...] Read more.
This paper uses an ultrasonic vibration-integrated array electrode for 301 stainless steel micro-hole drilling. The influence of machining parameters such as ultrasonic vibration amplitude, working voltage, pulse-off time and electrode feed rate on different processing characteristics are discussed. The experimental results show that the ultrasonic-assisted electrode array vibrating generates a periodic pressure difference for the electrolyte. The periodic pressure difference forms a pumping effect and a cavitation effect. The two effects can effectively renew the electrolyte in the machining gap and discharge the reaction product, gas and reaction heat from the gap. Machining speed can be increased by over 500% when the ultrasonic amplitude increases from 0.94 μm to 2.87 μm. Micro-hole drilling with the optimum experimental parameter combination of ultrasonic amplitude 2.87 μm, working voltage 11 V, pulse-off time 50 μs and electrode feed rate 5 μm/s can result in a minimum average diagonal length and a smaller amount of variation in diagonal length. It also improves the inlet and outlet taper angle of micro-holes. Full article
(This article belongs to the Special Issue New Frontiers in Magnetic Polishing and Electrochemical Technology)
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Article
Characteristics of the Polishing Effects for the Stainless Tubes in Magnetic Finishing with Gel Abrasive
Processes 2021, 9(9), 1561; https://doi.org/10.3390/pr9091561 - 01 Sep 2021
Viewed by 341
Abstract
Magnetic abrasive finishing (MAF) is a fast, high efficiency and high-precision polishing method on the surface machining of the metals. Furthermore, MAF also can be utilized to polish the stainless tubes in industrial applications; however, stainless tubes are often a non-magnetic material that [...] Read more.
Magnetic abrasive finishing (MAF) is a fast, high efficiency and high-precision polishing method on the surface machining of the metals. Furthermore, MAF also can be utilized to polish the stainless tubes in industrial applications; however, stainless tubes are often a non-magnetic material that makes it difficult for the magnetic field line to penetrate into the stainless tubes, thus reducing the magnetic forces in the inner tubes polishing. That is why stainless tubes are not easy to finish using traditional MAF. Therefore, magnetic finishing with gel abrasive (MFGA) applies gels mixed with steel grit and abrasives that were developed to improve the polishing efficiency and surface uniformity of the steel elements. In this study, a guar gum or silicone gel mixed with steel grit and silicon carbides are used as the magnetic abrasive gel to polish the stainless inner tubes. A DC motor was used to control the rotation speed of the chuck and an AC induction motor connected with an eccentric cam to produce the reciprocating motion of the workpiece were utilized to finish the inner surface of stainless tubes in the polishing process. The parameters of abrasive concentration, abrasive particle sizes, rotation speeds of motor and electric currents were used to investigate the surface roughness and the removal of materials from the stainless tubes. The experimental results showed that since guar gum had better fluidity than the silicone gel did, guar gum created excellent polishing efficiency in MFGA. Furthermore, the surface roughness of the stainless tube decreased from 0.646 μm Ra to below 0.056 μm Ra after processing for 30 min with the parameters of current 3A, gel abrasive with guar gum, rotational speed 1300 rpm and vibration frequency 4 Hz. Full article
(This article belongs to the Special Issue New Frontiers in Magnetic Polishing and Electrochemical Technology)
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Article
Feedback Control of Melt Pool Area in Selective Laser Melting Additive Manufacturing Process
Processes 2021, 9(9), 1547; https://doi.org/10.3390/pr9091547 - 30 Aug 2021
Viewed by 550
Abstract
Selective laser melting (SLM), a metal powder fusion additive manufacturing process, has the potential to manufacture complex components for aerospace and biomedical implants. Large-scale adaptation of these technologies is hampered due to the presence of defects such as porosity and part distortion. Nonuniform [...] Read more.
Selective laser melting (SLM), a metal powder fusion additive manufacturing process, has the potential to manufacture complex components for aerospace and biomedical implants. Large-scale adaptation of these technologies is hampered due to the presence of defects such as porosity and part distortion. Nonuniform melt pool size is a major cause of these defects. The melt pool size changes due to heat from the previous powder bed tracks. In this work, the effect of heat sourced from neighbouring tracks was modelled and feedback control was designed. The objective of control is to regulate the melt pool cross-sectional area rejecting the effect of heat from neighbouring tracks within a layer of the powder bed. The SLM process’s thermal model was developed using the energy balance of lumped melt pool volume. The disturbing heat from neighbouring tracks was modelled as the initial temperature of the melt pool. Combining the thermal model with disturbance model resulted in a nonlinear model describing melt pool evolution. The PID, a classical feedback control approach, was used to minimize the effect of intertrack disturbance on the melt pool area. The controller was tuned for the desired melt pool area in a known environment. Simulation results revealed that the proposed controller regulated the desired melt pool area during the scan of multiple tracks of a powder layer within 16 milliseconds and within a length of 0.04 mm reducing laser power by 10% approximately in five tracks. This reduced the chance of pore formation. Hence, it enhances the quality of components manufactured using the SLM process, reducing defects. Full article
(This article belongs to the Special Issue New Frontiers in Magnetic Polishing and Electrochemical Technology)
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