Advanced Manufacturing and Surface Technology, 2nd Edition

Journal Name	Impact Factor	CiteScore	Launched Year	First Decision (median)	APC
Coatings coatings	2.8	5.4	2011	13 Days	CHF 2600	Submit
Journal of Manufacturing and Materials Processing jmmp	3.3	5.2	2017	15.9 Days	CHF 1800	Submit
Lubricants lubricants	2.9	4.5	2013	15.6 Days	CHF 2600	Submit
Machines machines	2.5	4.7	2013	17.6 Days	CHF 2400	Submit
Materials materials	3.2	6.4	2008	15.5 Days	CHF 2600	Submit

16 pages, 7985 KB

Open AccessArticle

Effect of Laser Energy Density on Surface Morphology, Composition and Cleaning Mechanism of TC1 Titanium Alloy During Nanosecond Laser Cleaning

by Yang Chen, Haixiang Sun, Xuecheng Li, Hongyan Song, Zexuan Han, Jinhao Nie, Donghe Zhang, Jie Xu and Bin Guo

Materials 2026, 19(9), 1695; https://doi.org/10.3390/ma19091695 - 22 Apr 2026

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Abstract

To remove the oxide layer of TC1 titanium alloys in an environmentally friendly and efficient manner, this study conducted experiments using a nanosecond pulsed laser to systematically investigate the influence of different laser energy densities on the cleaning effect. The results showed that [...] Read more.

To remove the oxide layer of TC1 titanium alloys in an environmentally friendly and efficient manner, this study conducted experiments using a nanosecond pulsed laser to systematically investigate the influence of different laser energy densities on the cleaning effect. The results showed that the oxide layer could be completely removed at an energy density of 6.37 J/cm², with the surface oxygen element content reduced to 4.87%. The macroscopic surface presented a silvery metallic luster. Moreover, the roughness decreased significantly with the increase in energy density. At 6.37 J/cm², the surface roughness dropped to 0.37 µm. The mechanism of removing the oxide layer of TC1 titanium alloy mainly includes laser ablation and plasma impact. At energy densities ranging from 2.55 J/cm² to 6.37 J/cm², the cleaning mechanism was mainly laser ablation. When the energy density exceeded 6.37 J/cm², the cleaning mechanism gradually shifted from laser ablation to plasma impact as the dominant factor. Meanwhile, the microhardness of the samples after laser cleaning was basically consistent with that of the samples subjected to mechanical grinding, which provides a basis for a nanosecond pulsed laser to replace traditional methods for oxide layer cleaning. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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23 pages, 5229 KB

Open AccessArticle

Experimental Investigation of Surface Integrity Analysis Using Machine Learning for Nano-Powder Mixed Electrical Discharge Machining

by Amreeta R. Kaigude, Nitin K. Khedkar and Vijaykumar S. Jatti

J. Manuf. Mater. Process. 2026, 10(4), 115; https://doi.org/10.3390/jmmp10040115 - 28 Mar 2026

Viewed by 559

Abstract

This research investigates the optimization of surface integrity in powder-mixed electrical discharge machining (PMEDM) through the innovative use of Jatropha biodielectric fluid enhanced with titanium dioxide (TiO₂) nanoparticles. A comprehensive experimental framework was developed using design expert software (DOE) with Response [...] Read more.

This research investigates the optimization of surface integrity in powder-mixed electrical discharge machining (PMEDM) through the innovative use of Jatropha biodielectric fluid enhanced with titanium dioxide (TiO₂) nanoparticles. A comprehensive experimental framework was developed using design expert software (DOE) with Response Surface Methodology (RSM) to systematically analyze the machining of AISI D2 tool steel using copper electrodes. The study examined five critical process parameters, gap current (Ip), pulse-on duration (Ton), pulse-off time (Toff), gap voltage (V), and powder concentration, evaluating their combined effects on surface roughness (SR), surface crack density (SCD), and residual stress characteristics. Advanced characterization techniques including scanning electron microscopy (SEM) were employed to analyze surface topography and subsurface microstructural changes. The optimization process successfully identified optimal machining conditions of current = 9 A, Ton = 100 µs, Toff = 10 µs, and gap voltage = 65 V, achieving exceptional surface quality with a minimum surface roughness of 3.22 µm. Remarkably, these optimized parameters resulted in crack-free surfaces with zero surface crack density and minimal residual stress values across the 2θ range of 90° to 180°. To enhance predictive capabilities, supervised machine learning algorithms were implemented to model surface roughness behavior. Comparative analysis of classification algorithms demonstrated that Support Vector Machine (SVM), k-Nearest Neighbors (kNNs), and Gaussian Naïve Bayes achieved superior performance with F1-scores of 0.88 and prediction accuracies of 90%. The integration of sustainable Jatropha biodielectric with TiO₂ nanoparticles represents a significant advancement in environmentally conscious precision machining, while the machine learning approach establishes a robust framework for intelligent process optimization and quality prediction in advanced manufacturing applications. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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14 pages, 3902 KB

Open AccessArticle

Influence of Oxygen Flow and Stoichiometry on Optical Properties and Damage Resistance of Hafnium Oxide Thin Films

by Amira Guediche, Saaxewer Diop, Raluca A. Negres, Leonardus Bimo Bayu Aji and Colin Harthcock

Coatings 2026, 16(3), 376; https://doi.org/10.3390/coatings16030376 - 17 Mar 2026

Viewed by 527

Abstract

Hafnium oxide (HfO₂) is predominantly used as a high-index material in multi-layer dielectric coatings for high-peak- and high-average-power lasers, but laser damage often initiates within the HfO₂ layers despite their wide bandgap. Oxygen deficiency during deposition can introduce vacancy-related sub-bandgap [...] Read more.

Hafnium oxide (HfO₂) is predominantly used as a high-index material in multi-layer dielectric coatings for high-peak- and high-average-power lasers, but laser damage often initiates within the HfO₂ layers despite their wide bandgap. Oxygen deficiency during deposition can introduce vacancy-related sub-bandgap states and absorptive defects, lowering damage resistance. This study investigates how oxygen flow during HfO₂ deposition with ion beam sputtering (IBS) affects its stoichiometry, defect formation, and nanosecond laser-induced damage threshold (LIDT) and whether single-layer trends predict multilayer performance. Single layers were deposited at varying oxygen flows, characterized for optical and structural properties, and tested for the LIDT at 1064 nm and 355 nm. Increasing oxygen flow drove the layer toward near-stoichiometric HfO₂, reduced the refractive index, and altered the density of surface pinhole-like features. The single-layer LIDT at 355 nm increased with oxygen, whereas the 1064 nm LIDT was comparatively less sensitive to oxygen flow, consistent with the wavelength-dependent roles of absorptive precursors and microstructural defects. In contrast, a HfO₂-based high-reflector (HR) showed a higher LIDT at lower oxygen flow, indicating that the family of damage precursors changes between single layers and multilayers; in stacks, structural properties such as stress, gas entrapment and thermal dissipation may outweigh the isolated absorptive defects found in single layers. These results demonstrate that the optimal oxygen flow condition depends on both LIDT wavelength and film architecture. We identified, for single layers, a 15–35 sccm window for maximizing the 1064 nm LIDT and a high-flow optimum (45 sccm) for the 355 nm LIDT and, for 355 nm HR stacks, a distinct lower-flow regime (~10 sccm). Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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15 pages, 10766 KB

Open AccessArticle

The Combustion Behaviors and Flame-Retardant Mechanisms of Cu Coating as Protection for Titanium Alloys

by Jianjun Li, Shujing Wang, Pengfei Jin, Cheng Zhang and Congzheng Wang

Materials 2026, 19(5), 944; https://doi.org/10.3390/ma19050944 - 28 Feb 2026

Viewed by 390

Abstract

This study investigates the influence of highly thermally conductive coatings on the combustion thresholds of a TC4 titanium alloy, aiming to address the flame-retardant protection requirements for titanium alloys. The findings reveal that, in terms of combustion thermodynamics, as the thickness of the [...] Read more.

This study investigates the influence of highly thermally conductive coatings on the combustion thresholds of a TC4 titanium alloy, aiming to address the flame-retardant protection requirements for titanium alloys. The findings reveal that, in terms of combustion thermodynamics, as the thickness of the copper coating increases from 100 μm to 300 μm, the critical ignition power rises by 125–170 W compared to the substrate (235 W). Additionally, the critical oxygen pressure increases by 0.21–0.51 MPa relative to the substrate (0.03 MPa), and the ignition temperature is elevated by 119–184 K above that of the substrate (848.80 K). This phenomenon is primarily due to the high thermal diffusivity of copper. Increased coating thickness further enhances heat dissipation, significantly suppressing the local heat accumulation rate and thereby improving the coating’s combustion resistance. In terms of combustion kinetics, under fixed experimental conditions, the copper coating extends the ignition delay time by 0.670 s and reduces the combustion propagation rate by approximately 21% compared to the substrate (26.772 mm/s). The post-combustion microstructural analysis indicates that during the reaction process, the copper coating forms a TiCu₂Al-type intermetallic compound (Ti_0.5Al_0.5)Cu. This structure exerts an “anchoring” effect on the substrate material, decreases the Ti/O reaction efficiency, and consequently achieves effective flame retardancy. These findings inform the subsequent design and optimization of copper-based abradable coatings with enhanced combustion resistance. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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10 pages, 3929 KB

Open AccessArticle

Dual-Scale Femtosecond-Laser Stripe Microstructures Regulate Fibroblast Behavior for Functional Soft-Tissue Control on Titanium Mesh Implants

by Jiaru Zhang, Tao Yu, Xinran Zhang, Jin Yang and Libin Lu

Coatings 2026, 16(3), 280; https://doi.org/10.3390/coatings16030280 - 26 Feb 2026

Viewed by 345

Abstract

Soft-tissue management is critical for guided bone regeneration (GBR), yet conventional titanium meshes lack the ability to regionally regulate fibroblast behavior where opposite biological responses are needed. Here, we fabricated two femtosecond-laser patterned stripe topographies on titanium using a unidirectional scanning strategy with [...] Read more.

Soft-tissue management is critical for guided bone regeneration (GBR), yet conventional titanium meshes lack the ability to regionally regulate fibroblast behavior where opposite biological responses are needed. Here, we fabricated two femtosecond-laser patterned stripe topographies on titanium using a unidirectional scanning strategy with parameter tuning, generating LSFL with a periodicity of 820 ± 30 nm and micro-grooves with a periodicity of 4.7 ± 0.1 μm. Surface morphology and physicochemical properties were characterized by SEM/AFM, XPS, microhardness testing, and wettability measurements. Human gingival fibroblasts (HGF-1) were used to assess adhesion, cytoskeletal organization, spreading area, and proliferation (CCK-8). The submicron LSFL promoted robust fibroblast adhesion, aligned cytoskeletal organization, larger spreading areas, and higher proliferation, whereas the micro-groove surface markedly restricted spreading and was associated with poorer cytoskeletal organization and lower proliferation. Alternating patterned regions further demonstrated geometry-driven spatial selectivity, with preferential cell occupation on LSFL stripes. These findings support a fabrication-ready surface-engineering strategy to synchronize rapid soft-tissue sealing while restricting unwanted fibroblast advancement at defined regions, offering a promising route toward more predictable GBR outcomes. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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19 pages, 5302 KB

Open AccessArticle

Experimental Study on Surface and Subsurface Defect Characteristics of 8Cr4Mo4V Bearing Steel After Grinding

by Junjun Liu, Xiaoquan Shi, Haixiang Zeng, Chenhui Sun, Bohan Zhang, Zhihu Zhang, Yazhou Sun and Haitao Liu

Machines 2026, 14(2), 236; https://doi.org/10.3390/machines14020236 - 19 Feb 2026

Viewed by 463

Abstract

Due to its excellent high-temperature resistance and fatigue properties, 8Cr4Mo4V high-temperature bearing steel has become a critical material for aero-engine main shaft bearings. Consequently, the surface integrity of this material after grinding directly determines the service performance and fatigue life of the bearings. [...] Read more.

Due to its excellent high-temperature resistance and fatigue properties, 8Cr4Mo4V high-temperature bearing steel has become a critical material for aero-engine main shaft bearings. Consequently, the surface integrity of this material after grinding directly determines the service performance and fatigue life of the bearings. To address the lack of clarity regarding the correlation between grinding process parameters and defect characteristics under strong thermal–mechanical coupling, systematic grinding experiments were conducted in this study. Scanning Electron Microscopy (SEM) and white light interferometry were employed to observe the ground surface morphology and subsurface damage characteristics under various process parameters. On this basis, the influence of key parameters—such as wheel linear speed and grinding depth—on the formation and distribution of defects, including micro-cracks and material spalling, was analyzed in depth. Through qualitative and quantitative analyses, this study aims to elucidate the mechanisms by which grinding parameters affect machining defects, thereby providing experimental data and references for the optimization of the grinding process for this type of material. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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15 pages, 3785 KB

Open AccessArticle

A Sustainable Manufacturing Approach: Experimental and Machine Learning-Based Surface Roughness Modelling in PMEDM

by Vaibhav Ganachari, Aleksandar Ašonja, Shailesh Shirguppikar, Ruturaj U. Kakade, Mladen Radojković, Blaža Stojanović and Aleksandar Vencl

J. Manuf. Mater. Process. 2026, 10(1), 10; https://doi.org/10.3390/jmmp10010010 - 29 Dec 2025

Cited by 1 | Viewed by 758

Abstract

The powder-mixed electric-discharge machining (PMEDM) process has been the focus of researchers for quite some time. This method overcomes the constraints of conventional machining, viz., low material removal rate (MRR) and high surface roughness (SR) in hard-cut materials, tool failure, and a high [...] Read more.

The powder-mixed electric-discharge machining (PMEDM) process has been the focus of researchers for quite some time. This method overcomes the constraints of conventional machining, viz., low material removal rate (MRR) and high surface roughness (SR) in hard-cut materials, tool failure, and a high tool wear ratio (TWR). However, to determine the optimal machining parameter levels for improving MRR, surface finish must be measured during actual experimentation using various parameter levels across different materials. It is a very costly and time-consuming process for industries. However, in the age of Industry 4.0 and artificial intelligence machine learning (AI-ML), it provides an efficient solution to real manufacturing problems when big data is available. In this study, experimentation was conducted on AISI D2 steel using the PMEDM process for SR analysis with different parameters, viz. current, voltage, cycle time (T_On), powder concentration (PC), and duty factor (DF). Moreover, machine learning models were used to predict SR values for selected parameter levels in the PMEDM process. In this research, Gaussian process regression (GPR) with a squared exponential kernel, support vector machines, and ensemble regression models were used for computational analysis. The results of this work showed that Gaussian regression, support vector machine, and ensemble regression achieved 95%, 92%, and 83% accuracy, respectively. The GPR model achieved the best predictive performance among these three models. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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21 pages, 8090 KB

Open AccessArticle

Research on Milling Burrs of ALSI304 Stainless Steel with Consideration of Tool Eccentricity

by Can Liu, Jiajia He, Runhua Lu, Zhiyi Mo, Huanlao Liu and Ningxia Yin

J. Manuf. Mater. Process. 2025, 9(12), 390; https://doi.org/10.3390/jmmp9120390 - 27 Nov 2025

Viewed by 751

Abstract

Burrs are a significant machining defect affecting the quality of precision parts, and tool eccentricity may substantially influence milling burrs. Using AISI 304 stainless steel as the workpiece material, a three-dimensional thermo-mechanical coupled model for slot milling was constructed based on an explicit [...] Read more.

Burrs are a significant machining defect affecting the quality of precision parts, and tool eccentricity may substantially influence milling burrs. Using AISI 304 stainless steel as the workpiece material, a three-dimensional thermo-mechanical coupled model for slot milling was constructed based on an explicit dynamics model. Combining the Johnson–Cook (J-C) constitutive model with the J-C shear failure criterion, simulations were conducted to obtain burr dimensions, cutting temperature distributions, and cutting force waveforms under different tool eccentricity directions and magnitudes. Results: As the eccentricity increases, the temperature of the top burr rises, and both the width of the top burr and the thickness of the exit side burr significantly increase. Under simulated conditions, the width of the top burr in down milling side increased by up to 70%. The burr dimensions under different eccentricity directions can differ by approximately 40%. Groove milling experiments revealed similar burr shapes between experimental and simulated results. Furthermore, the simulated cutting force waveforms aligned with those in the literature, indicating the reliability of the simulation outcomes. Based on these findings, it can be concluded that tool eccentricity significantly affects the dimensions of top burrs and exit side burrs. The width of top burrs and the thickness of exit side burrs are positively correlated with the tool eccentricity distance, while exit bottom burrs remain unaffected by eccentricity. These research results provide valuable reference for burr suppression in practical machining operations. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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19 pages, 7131 KB

Open AccessArticle

Evaluation of Machining Parameters in Turning Al7075-T6 Aluminum Alloy Using Dry, Flooded, and Cryogenic Cutting Fluid Conditions

by Santiago Medina, Marcela Acuña-Rivera, Santiago Castellanos and Kleber Castro

J. Manuf. Mater. Process. 2025, 9(10), 328; https://doi.org/10.3390/jmmp9100328 - 7 Oct 2025

Viewed by 3061

Abstract

Production industries create high-quality products through effective machining precision, lead times, productivity, cost benefits, and implementing sustainable manufacturing practices. This study compares the effect of cryogenic CO₂ as a cutting fluid with a flooded conventional system and dry turning on the surface [...] Read more.

Production industries create high-quality products through effective machining precision, lead times, productivity, cost benefits, and implementing sustainable manufacturing practices. This study compares the effect of cryogenic CO₂ as a cutting fluid with a flooded conventional system and dry turning on the surface roughness, early-stage tool phenomena (including adhesion, material transfer, and built-up edge (BUE) formation), and the chip morphology of aluminum 7075-T6. Taguchi’s L9 orthogonal array is applied to identify the optimal cutting parameters that minimize surface roughness (Ra). Cutting speed (Vc), feed rate (f), depth of cut (ap), and the type of cutting fluid condition were defined at three levels. The surface roughness (Ra) was determined, and the built-up edge (BUE) and chip morphology were evaluated. Moreover, SEM and energy-dispersive X-ray spectroscopy (EDX) were employed to characterize the machined surface and the cutting tools. The optimal values for the cryogenic cooling and cutting parameters are as follows: 220 m/min (Vc), 0.05 mm/rev (f), and 0.5 mm (ap). These conditions yield a surface roughness mean (Ra) of 0.736 µm, improving the surface roughness by 10.57% compared with the lowest Ra value from all of the tests. In addition, ANOVA showed the feed rate to be the most significant cutting parameter over surface roughness under the given conditions. Regarding chip morphology, snarled chip shapes are associated with low surface roughness values. The results indicate that cryogenic cutting fluid enhances the machined surface quality and reduces the built-up edge compared with dry and flooded conditions. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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22 pages, 7901 KB

Open AccessArticle

Research on the Load Characteristics of Aerostatic Spindle Considering Straightness Errors

by Guoqing Zhang, Yu Guo, Guangzhou Wang, Wenbo Wang, Youhua Li, Hechun Yu and Suxiang Zhang

Lubricants 2025, 13(8), 326; https://doi.org/10.3390/lubricants13080326 - 26 Jul 2025

Viewed by 990

Abstract

As the core component of ultra-precision machine tools, the manufacturing errors of aerostatic spindles are inevitable due to the limitations of machining and assembly processes, and these errors significantly affect the spindle’s static and dynamic performance. To address this issue, a force model [...] Read more.

As the core component of ultra-precision machine tools, the manufacturing errors of aerostatic spindles are inevitable due to the limitations of machining and assembly processes, and these errors significantly affect the spindle’s static and dynamic performance. To address this issue, a force model of the unbalanced air film, considering the straightness errors of the rotor’s radial and thrust surfaces, was constructed. Unlike conventional studies that rely solely on idealized error assumptions, this research integrates actual straightness measurement data into the simulation process, enabling a more realistic and precise prediction of bearing performance. Rotors with different tolerance specifications were fabricated, and static performance simulations were carried out based on the measured geometry data. An experimental setup was built to evaluate the performance of the aerostatic spindle assembled with these rotors. The experimental results were compared with the simulation outcomes, confirming the validity of the proposed model. To further quantify the influence of straightness errors on the static characteristics of aerostatic spindles, ideal functions were used to define representative manufacturing error profiles. The results show that a barrel-shaped error on the radial bearing surface can cause a load capacity variation of up to 46.6%, and its positive effect on air film load capacity is more significant than that of taper or drum shapes. For the thrust bearing surface, a concave-shaped error can lead to a load capacity variation of up to 13.4%, and its enhancement effect is superior to those of the two taper and convex-shaped errors. The results demonstrate that the straightness errors on the radial and thrust bearing surfaces are key factors affecting the radial and axial load capacities of the spindle. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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48 pages, 7567 KB

Open AccessReview

Research Progress on Microstructure, Mechanical Properties, and Strengthening Mechanisms of In Situ-Synthesized Ceramic-Reinforced Titanium Matrix Composite Coatings via Laser Cladding

by Min Wen, Boqiang Jiang, Xianyin Duan and Dingding Xiang

Coatings 2025, 15(7), 815; https://doi.org/10.3390/coatings15070815 - 11 Jul 2025

Cited by 11 | Viewed by 3950

Abstract

The laser cladding (LC) of titanium matrix composite coatings (TMCCs) on titanium components not only effectively enhances the wear resistance, fatigue resistance, corrosion resistance, and biocompatibility of titanium and its alloys, but also circumvents the incompatibility and low bonding strength issues associated with [...] Read more.

The laser cladding (LC) of titanium matrix composite coatings (TMCCs) on titanium components not only effectively enhances the wear resistance, fatigue resistance, corrosion resistance, and biocompatibility of titanium and its alloys, but also circumvents the incompatibility and low bonding strength issues associated with other metallic composite coatings. While the incorporation of ceramic particles is a critical strategy for improving the coating performance, the limited interfacial bonding strength between ceramic particles and the matrix has historically constrained its advancement. To further elevate its performance and meet the demands of components operating in harsh environments, researchers worldwide have employed LC to synthesize in situ hard ceramic reinforcements such as TiC, TiB, TiN, and others within TMCCs on titanium substrates. This approach successfully addresses the aforementioned challenges, achieving coatings that combine a high interfacial bonding strength with superior mechanical properties. This paper provides a comprehensive review of the processing techniques, phase composition, microstructure, and mechanical properties of in situ-synthesized ceramic-reinforced TMCCs via LC on titanium components, with a focused summary of their strengthening mechanisms. Furthermore, it critically discusses the challenges and future prospects for advancing this technology. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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30 pages, 18545 KB

Open AccessArticle

Uniform Coverage Trajectory Planning for Polishing of Equation-Free Surfaces

by Linqiang Gong, Longxiang Li, Lei Zhang, Cheng Fan and Nianju Li

Machines 2025, 13(7), 568; https://doi.org/10.3390/machines13070568 - 30 Jun 2025

Cited by 3 | Viewed by 1381

Abstract

Conventional surface polishing trajectory generation relies on solving the plane trajectory equation in conjunction with the surface equation to obtain a surface polishing trajectory when the surface equation is known. However, in practical polishing processes, there exist equation-free surfaces which cannot be described [...] Read more.

Conventional surface polishing trajectory generation relies on solving the plane trajectory equation in conjunction with the surface equation to obtain a surface polishing trajectory when the surface equation is known. However, in practical polishing processes, there exist equation-free surfaces which cannot be described by equations and the generation of polishing trajectories on equation-free surfaces cannot be realized by an equation-solving strategy. In this paper, a polishing trajectory generation method for equation-free surfaces modeled by meshes based on the trajectory mapping strategy is proposed. As the calculation process for the coverage area of polishing trajectories requires invoking surface curvature information, this paper proposes a mesh surface curvature fitting algorithm. Regarding the problem of non-uniformity in the coverage area of polishing trajectories caused by surface curvature fluctuations, an algorithm for adjusting the position of polishing trajectory points on mesh surfaces is proposed, which enables the mapped trajectory points to be adjusted according to the required overlapping coverage area of the adjacent polishing trajectories. The uniform coverage of multiple polishing trajectories for rotationally symmetric workpieces is achieved by the proposed trajectory point position adjustment algorithm. Through experiment and analysis, it is verified that the proposed algorithm for uniform coverage of polishing trajectories can obtain better polishing results with the same polishing time. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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21 pages, 8909 KB

Open AccessArticle

A Methodology for Acceleration Signals Segmentation During Forming Regular Reliefs Patterns on Planar Surfaces by Ball Burnishing Operation

by Stoyan Dimitrov Slavov and Georgi Venelinov Valchev

J. Manuf. Mater. Process. 2025, 9(6), 181; https://doi.org/10.3390/jmmp9060181 - 29 May 2025

Viewed by 1400

Abstract

In the present study, an approach for determining the different states of ball burnishing (BB) operations aimed at forming regular reliefs’ patterns on planar surfaces is introduced. The methodology involves acquiring multi-axis accelerometer data from CNC-driven milling machine to capture the dynamics of [...] Read more.

In the present study, an approach for determining the different states of ball burnishing (BB) operations aimed at forming regular reliefs’ patterns on planar surfaces is introduced. The methodology involves acquiring multi-axis accelerometer data from CNC-driven milling machine to capture the dynamics of the BB tool and workpiece, mounted on the machine table. Following data acquisition from an AISI 304 stainless steel workpiece, which is subjected to BB treatments at different toolpaths and feed rates, the recorded signals are preprocessed through noise reduction techniques, DC component removal, and outlier correction. The refined data are then transformed using a root mean square (RMS) operation to simplify further analysis. A Gaussian Mixture Model (GMM) is subsequently employed to decompose the compressed RMS signal into distinct components corresponding to various operational states during BB. The experimental trials at feed rates of 500 and 1000 mm/min reveal that increased feed rates enhance the distinguishability of these states, thus leading to an augmented number of statistically significant components. The results obtained from the proposed GMM based algorithm applied on compressed RMS accelerations signals is compared with two other methods, i.e., Short-Time Fourier Transforms and Continuous Wavelet Transform. The results from the comparison show that the proposed GMM method has the advantage of segmenting three to five different states of the BB-process from nonstationary accelerations signals measured, while the other tested methods are capable only to distinguish the state of work of the deforming tool and state of its rapid (re-)positioning between the areas of working, when there is no contact between the BB-tool and workpiece. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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15 pages, 4008 KB

Open AccessArticle

Optimization of Process Parameters in Electropolishing of SS 316L Utilizing Taguchi Robust Design

by Muhammad Kemal Syahputra, Kartika Nur ‘Anisa’, Rizky Astari Rahmania, Farazila Yusof, Pradeep Dixit, Muslim Mahardika and Gunawan Setia Prihandana

J. Manuf. Mater. Process. 2025, 9(4), 127; https://doi.org/10.3390/jmmp9040127 - 11 Apr 2025

Cited by 3 | Viewed by 4356

Abstract

In electropolishing, the material removal rate is frequently neglected, as this process is primarily focused on surface finish, and yet, it is crucial for manufacturing metallic sheets. Solutions are required to enhance the material removal rate while maintaining surface quality. This work introduces [...] Read more.

In electropolishing, the material removal rate is frequently neglected, as this process is primarily focused on surface finish, and yet, it is crucial for manufacturing metallic sheets. Solutions are required to enhance the material removal rate while maintaining surface quality. This work introduces an electropolishing technique that involves suspending ethanol in an electrolyte solution and employing a magnetic field during machining processes. The Taguchi approach is utilized to determine the ideal process parameters for enhancing the material removal rate of SS 316L electropolishing through a L9 orthogonal array. Pareto analysis of variance (ANOVA) is utilized to examine the four parameters of the machining process: applied voltage, ethanol concentration, machining gap variation, and the magnetic field of the electrolyte. The results demonstrate that the applied voltage, the incorporation of ethanol in electropolishing, and a reduced machining gap significantly increase the material removal rate; however, the introduction of a magnetic field did not notably increase the material removal rate. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

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