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Coatings
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Recent Advances in the Machining of Metals and Composites
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Recent Advances in the Machining of Metals and Composites

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Surface Characterization, Deposition and Modification".

Deadline for manuscript submissions: 28 February 2025 | Viewed by 9742

Special Issue Editors

Dr. Muhammad Aamir

E-Mail Website
Guest Editor
School of Engineering, Edith Cowan University, Joondalup, WA 6027, Australia
Interests: advanced manufacturing; machining aerospace structural materials; characterization of materials; optimization
Special Issues, Collections and Topics in MDPI journals
Dr. Majid Tolouei-Rad

E-Mail Website
Guest Editor
School of Engineering, Edith Cowan University, Joondalup, WA 6027, Australia
Interests: robotics and automation; CAD/CAM; manufacturing processes and systems; processing of engineering materials; CAD-based fixture/machine design; design of modular special purpose machines; design and implementation of robots; heat treatment analysis of metallic materials
Dr. Riaz Muhammad

E-Mail Website
Co-Guest Editor
Mechanical Engineering Department, College of Engineering, University of Bahrain, Isa Town 32038, Bahrain
Interests: manufacturing processes; finite Element modelling; advanced materials; optimization tools; characterization of materials; hybrid machining processes; entropy optimization; solder alloys

Special Issue Information

Dear Colleagues,

The success of many manufacturing operations depends on proper planning and implementation. Therefore, efficiently performing machining operations is a deciding factor in their success and competitiveness in many manufacturing industries. In this regard, both researchers and the industry are seeking innovative methods for improving machining operations based on tool geometry, tool materials and coatings and reducing machining time for high productivity. This Special Issue focuses on recent advances in the conventional and nonconventional machining of metals and composites materials to provide academic and industrial researchers with a platform to share high-quality original research and critical review articles. Articles focusing on uncoated and coated tools, modelling and the optimization of machining processes are welcome. Additional topics of articles include but are not limited to:

  • Machining of metal and composite materials;
  • Machining quality and defect assessments in materials;
  • Uncoated and coated tools for machining processes;
  • Failure mechanisms and tool wear modes of cutting tools;
  • Modelling, simulation and optimization of the machining process;
  • Characterization of advanced coating materials;
  • Health and safety considerations in machining operations.

Dr. Muhammad Aamir
Dr. Majid Tolouei-Rad
Dr. Riaz Muhammad
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 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. Coatings 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

  • machining operations
  • metals and composites
  • coating materials
  • cutting tools
  • tool wear
  • modelling optimization

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (5 papers)

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Research

19 pages, 11831 KiB  
Article
Fabrication of Vitrified Bond Diamond Grinding Wheel via LCD Photopolymerization
by Zhaoqi Chen, Na Xiao, Ping Han, Zhao Wang and Guoju Bai
Coatings 2023, 13(12), 2079; https://doi.org/10.3390/coatings13122079 - 13 Dec 2023
Cited by 1 | Viewed by 1398
Abstract
In this paper, a liquid crystal display (LCD) photopolymerization method is proposed, and a vitrified bond diamond grinding wheel is successfully prepared. A high-performance vitrified bond was obtained by melting SiO2-B2O3-Al2O3-Na2O [...] Read more.
In this paper, a liquid crystal display (LCD) photopolymerization method is proposed, and a vitrified bond diamond grinding wheel is successfully prepared. A high-performance vitrified bond was obtained by melting SiO2-B2O3-Al2O3-Na2O ceramic raw materials and used for grinding wheel preparation. LCD photopolymerization technology is characterized by high precision in shaping, fast processing speed, and superior quality, making it a promising technology for fabricating vitrified bond diamond grinding wheels. The preparation of vitrified bond slurry with high solid content and low viscosity was extensively investigated to meet the fabrication requirements. The effects of dispersant, the particle size of the vitrified bond, and solid content on the viscosity of the slurry were systematically analyzed. The vitrified bond slurry with solid content up to 65 wt.% (approximately 45.5 vol.%) was successfully prepared and met the requirements for printing. Furthermore, we explored the optimal formulation of the grinding wheel, debinding and sintering conditions, sintering temperature, grit-to-bond ratio, and the evaluation of the grinding performance of the wheel on hard and brittle materials, such as silicon carbide ceramic. Vitrified bond and abrasive slurry systems with a solid content of 65 wt.% (approximately 42.8 vol.%) were prepared. The results show that the vitrified bond diamond grinding wheel exhibits optimal comprehensive performance, with a sintering temperature of 680 °C and a grit-to-bond ratio of 4:6. The minimum surface roughness of the workpiece after grinding was 1.767 μm, the material removal rate was 5.08 mg/s, the grinding ratio was 9.78, and the friction coefficient was stabilized at about 0.5 during grinding. This paper guides the manufacturing of vitrified bond diamond grinding wheels via LCD photopolymerization. Full article
(This article belongs to the Special Issue Recent Advances in the Machining of Metals and Composites)
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15 pages, 4184 KiB  
Article
Experimental Study on Cutting Force and Surface Integrity of TC4 Titanium Alloy with Longitudinal Ultrasonic-Assisted Milling
by Qingqing Lü, Yongbo Chai, Liquan Yang, Xiaodong Liu, Guangxi Li and Daohui Xiang
Coatings 2023, 13(10), 1725; https://doi.org/10.3390/coatings13101725 - 2 Oct 2023
Cited by 4 | Viewed by 1336
Abstract
The ultrasonic vibration-assisted milling process was used to study the difficult-to-machine aerospace material titanium alloy TC4 and explore the milling parameters that fit the processing. Based on the orthogonal experimental method, the changes in cutting force, roughness, and surface morphology under conventional and [...] Read more.
The ultrasonic vibration-assisted milling process was used to study the difficult-to-machine aerospace material titanium alloy TC4 and explore the milling parameters that fit the processing. Based on the orthogonal experimental method, the changes in cutting force, roughness, and surface morphology under conventional and ultrasonic-assisted milling conditions were studied, and the relationship between various processing parameters and their effects was obtained. The results showed that the cutting force was most affected by the feed per tooth and cutting depth. Adding ultrasonic vibration could change the surface texture and significantly impact roughness. By adding an appropriate amplitude of ultrasonic-assisted milling, the maximum average cutting force can be reduced by more than 20.66%, and the maximum surface roughness can be reduced by 44.23%, making the workpiece surface produce regular “sine/cosine” patterns and improving the surface quality of the workpiece. Compared with conventional milling, the deformation layer of the workpiece slightly increased under ultrasonic-assisted milling. The cutting force and surface roughness of titanium alloy TC4 under ultrasonic-assisted milling were reduced. A reasonable selection of processing parameters can further improve cutting force and other parameters, providing a reference basis for the processing of aerospace materials. Full article
(This article belongs to the Special Issue Recent Advances in the Machining of Metals and Composites)
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16 pages, 6862 KiB  
Article
Study of the Influence of Tool Wear of Two Drill Bits Manufactured with Different Coating Processes in Drilling Carbon/Glass Fiber Hybrid Composite Bounded with Epoxy Polymer
by Santiago Carlos Gutiérrez, María Desamparados Meseguer, Ana Muñoz-Sánchez and Norberto Feito
Coatings 2023, 13(8), 1440; https://doi.org/10.3390/coatings13081440 - 16 Aug 2023
Cited by 1 | Viewed by 1632
Abstract
Fiber Reinforced Polymer (FRP) laminates have been widely used in engineering applications in recent decades. This is mainly due to their superior mechanical properties compared to single-phase materials. High strength-to-weight ratio, high stiffness, and excellent corrosion and fatigue resistance are some of the [...] Read more.
Fiber Reinforced Polymer (FRP) laminates have been widely used in engineering applications in recent decades. This is mainly due to their superior mechanical properties compared to single-phase materials. High strength-to-weight ratio, high stiffness, and excellent corrosion and fatigue resistance are some of the attractive properties of these materials. In large structures, drilling composite panels is a typical operation to assemble different parts with mechanical fasteners. This operation severely threatens the quality of the holes and, therefore, the joint strength. This study aims to study the wear evolution of two drill bits manufactured with different coatings processes (chemical vapor deposition and physical vapor deposition) and their influence on the quality of the holes. A carbon/glass fiber sandwich structure was selected as the workpiece, and a high-speed machine center was used to drill 1403 holes per tool in the laminates. The wear analysis of the tool was characterized in terms of flank wear and crater wear. For the delamination analysis caused by drilling, two types of delamination are identified (type I and II), and their values were quantified through the equivalent delamination factor (Fed). The results showed that, in general, the process used to apply the coating to the tool influences the wear mode and the delamination damage. The first tool, diamond coated with Chemical Vapor Deposition (CVD), showed more severe crater wear in the flank face and coating loss at the end of the cutting edges. However, with a Physical Vapor Deposition (PVD) coating process, the second tool presented flank wear more controlled but a more severe coating loss and edge rounding near the tip, producing further delamination. Using a supporting plate showed a reduction of delamination type I but not for delamination type II, which is related to edge rounding. Full article
(This article belongs to the Special Issue Recent Advances in the Machining of Metals and Composites)
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14 pages, 2710 KiB  
Article
Research on Tool Wear and Surface Integrity of CFRPs with Mild Milling Parameters
by Jun Qiu, Shunqi Zhang, Bo Li, Yi Li and Libiao Wang
Coatings 2023, 13(1), 207; https://doi.org/10.3390/coatings13010207 - 16 Jan 2023
Cited by 4 | Viewed by 2372
Abstract
Carbon fiber-reinforced polymer composites are widely used in aviation and aerospace applications due to their excellent mechanical properties. Numerous studies have focused on tool wear at extreme machining parameters (f ≥ 540 mm/min) to accelerate tool wear experiments. However, using mild machining parameters [...] Read more.
Carbon fiber-reinforced polymer composites are widely used in aviation and aerospace applications due to their excellent mechanical properties. Numerous studies have focused on tool wear at extreme machining parameters (f ≥ 540 mm/min) to accelerate tool wear experiments. However, using mild machining parameters is also instructive for current process production. To investigate the effect of wear on the surface integrity of CFRPs under mild parameters, a tool wear experiment on CFRPs was carried out at a conventional feed rate (f = 60 mm/min). The results show a cutting temperature increase of 47%, a cutting force increase of 53% and a flank wear width increase of 282% for PCD tools (with mild milling parameters) from 0 to 100 m of cutting length. As the cutting temperature reaches the glass transition temperature, Tg, during the stable wear stage, severe burrs and a large number of cavities appeared on the groove, and the subsurface with granular wear on flank wear land due to the transform of the matrix. Furthermore, Ra and Rz exhibit good indicators of cutting length and subsurface damage. Full article
(This article belongs to the Special Issue Recent Advances in the Machining of Metals and Composites)
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14 pages, 2992 KiB  
Article
Machining of Carbon Steel under Aqueous Environment: Investigations into Some Performance Measures
by Mushtaq Ali, Tahir Abdul Hussain Ratlamwala, Ghulam Hussain, Tauheed Shehbaz, Riaz Muhammad, Muhammad Aamir, Khaled Giasin and Danil Yurievich Pimenov
Coatings 2022, 12(8), 1203; https://doi.org/10.3390/coatings12081203 - 17 Aug 2022
Viewed by 1853
Abstract
In this study, a new machining approach (aqueous machining) is applied for mill machining and its performance is compared with traditional wet machining. AISI 1020 steel is employed as the test material and Taguchi statistical methodology is implemented to analyze and compare the [...] Read more.
In this study, a new machining approach (aqueous machining) is applied for mill machining and its performance is compared with traditional wet machining. AISI 1020 steel is employed as the test material and Taguchi statistical methodology is implemented to analyze and compare the performance of the two machining approaches. The cutting speed, feed rate, and depth of cut were the machining parameters used for both types of machining, while the selected response variables were surface roughness and hardness. Temperature variations were also recorded in aqueous machining. Compared with wet machining, aqueous machining resulted in lower surface roughness (up to 13%) for the same operating conditions and about 14% to 16% enhancement in hardness due to the formation of finer pearlite, as revealed by the microstructure analysis. Compared to the parent unmachined surface, the hardness of machined surfaces was 24% to 31% higher in wet machining and 44% to 51% higher in aqueous machining. Another benefit of aqueous machining was the energy gain, which ranged from 718 to 8615.96 J. This amount of heat energy can be used as waste heat for preheating domestic hot water, running the organic Rankine cycle with waste heat and preheating the inlet saline water for desalination, vacuum desalination, etc. If successfully implemented in the future, this idea will provide a step towards achieving sustainable machining by saving lubricants and toxic wastes in addition to saving energy for secondary applications. Full article
(This article belongs to the Special Issue Recent Advances in the Machining of Metals and Composites)
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