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Recent Advances in Surface Integrity with Machining and Milling
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Recent Advances in Surface Integrity with Machining and Milling

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Advanced Manufacturing".

Deadline for manuscript submissions: 28 February 2025 | Viewed by 7457

Special Issue Editor

Prof. Dr. Kazumasa Kawasaki

E-Mail Website
Guest Editor
Department of Technology and Engineering Management, Sanjo City University, 5002-5 Kamisugoro, Sanjo 955-0091, Japan
Interests: high-precision and high-performance power transmission devices; cutting of difficult-to-cut materials; design of mechanical elements; machining
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The surface integrity with machining and milling has long been recognized as having a significant impact on product performance, longevity and reliability. The surface integrity covers various areas, such as surface roughness, surface topography, nano- or microstructure alterations, and residual stresses. In addition, it causes microstructural, mechanical and chemical effects. Therefore, recent advances in surface integrity will be able to be effectively utilized and optimized in manufacturing processes. This topic is important to study for the improvement of the efficiency of machines.

Prof. Dr. Kazumasa Kawasaki
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. Machines 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

  • surface roughness
  • surface topography
  • residual stresses
  • milling
  • machining

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Published Papers (6 papers)

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Research

18 pages, 8365 KiB  
Article
Prediction of Delamination Defects in Drilling of Carbon Fiber Reinforced Polymers Using a Regression-Based Approach
by Mohammad Ghasemian Fard, Hamid Baseri, Aref Azami and Abbas Zolfaghari
Machines 2024, 12(11), 783; https://doi.org/10.3390/machines12110783 - 6 Nov 2024
Viewed by 417
Abstract
Carbon fiber-reinforced polymer (CFRP) structures have been increasingly used in various aerospace sectors due to their outstanding mechanical properties in recent years. However, the poor machinability of CFRP plates, combined with the inhomogeneous behavior of fibers, poses a challenge for manufacturers and researchers [...] Read more.
Carbon fiber-reinforced polymer (CFRP) structures have been increasingly used in various aerospace sectors due to their outstanding mechanical properties in recent years. However, the poor machinability of CFRP plates, combined with the inhomogeneous behavior of fibers, poses a challenge for manufacturers and researchers to define the critical factors and conditions necessary to ensure the quality of holes in CFRP structures. This study aims to analyze the effect of drilling parameters on CFRP delamination and to predict hole quality using a regression-based approach. The design of the experiment (DOE) was conducted using Taguchi’s L9 3-level orthogonal array. The input drilling variables included the feed rate, spindle speed, and three different drill types. A regression-based model using partial least squares (PLS) was developed to predict delamination defects during the drilling of CFRP plates. The PLS model demonstrated high accuracy in predicting delamination defects, with a Mean Squared Error (MSE) of 0.0045, corresponding to an accuracy of approximately 99.6%, enabling the rapid estimation of delamination. The model’s predictions were closely aligned with the experimental results, although some deviations were observed due to tool inefficiencies, particularly with end mill cutters. These findings offer valuable insights for researchers and practitioners, enhancing the understanding of delamination in CFRPs and identifying areas for further investigation. Full article
(This article belongs to the Special Issue Recent Advances in Surface Integrity with Machining and Milling)
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17 pages, 5199 KiB  
Article
Experimental Investigation and NSGA-III Multi-Criteria Optimization of 60CrMoV18-5 Cold-Work Tool Steel Machinability Under Dry CNC Hard Turning Conditions
by Nikolaos A. Fountas, Ioannis G. Papantoniou, Dimitrios E. Manolakos and Nikolaos M. Vaxevanidis
Machines 2024, 12(11), 772; https://doi.org/10.3390/machines12110772 - 3 Nov 2024
Viewed by 716
Abstract
This work concerns an experimental investigation dealing with the machinability of 60CrMoV18-5 cold-work tool steel under dry CNC hard turning conditions using a CBN cutting insert. A response surface experiment based on the central composite design was set to conduct dry CNC hard-turning [...] Read more.
This work concerns an experimental investigation dealing with the machinability of 60CrMoV18-5 cold-work tool steel under dry CNC hard turning conditions using a CBN cutting insert. A response surface experiment based on the central composite design was set to conduct dry CNC hard-turning experiments with three different levels for cutting conditions, cutting speed Vc (m/min), feed rate f (mm/rev), and depth of cut α (mm) while selecting main cutting force and surface roughness Ra as the two machinability responses. The results were analyzed by applying analysis of variance (ANOVA). The effect of cutting conditions on main cutting force and surface roughness was studied through contour plots. Full quadratic regression models were generated to model the relationships between inputs and outputs. Finally, the NSGA-III algorithm was applied to simultaneously optimize the selected machinability parameters by providing beneficial values for determining cutting conditions. The results have shown that surface roughness is mainly affected by feed rate and cutting speed, whereas main cutting force is affected by depth of cut and feed rate. Full article
(This article belongs to the Special Issue Recent Advances in Surface Integrity with Machining and Milling)
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15 pages, 17757 KiB  
Article
A Study on the Machinability and Environmental Effects of Milling AISI 5140 Steel in Sustainable Cutting Environments
by Tufan Zerooğlu, Ünal Değirmenci and Serhat Şap
Machines 2024, 12(7), 436; https://doi.org/10.3390/machines12070436 - 26 Jun 2024
Viewed by 1160
Abstract
AISI 5140 steel is an alloy frequently used in the manufacturing and automotive industries. This steel alloy is shaped using different manufacturing methods and cooling is required during this process. This research study included the milling of AISI 5140 steel utilizing various cutting [...] Read more.
AISI 5140 steel is an alloy frequently used in the manufacturing and automotive industries. This steel alloy is shaped using different manufacturing methods and cooling is required during this process. This research study included the milling of AISI 5140 steel utilizing various cutting settings and cooling/lubrication procedures. For this purpose, two cutting speeds (75–100 m/min), two feed rates (0.075–0.100 mm/rev), and four cooling media (dry, MQL, flood, nanofluid) were used. Then, 5% Mo nanoparticles were added to the nanofluid cutting fluid. Machinability and power consumption analyses were carried out using the input parameters selected in light of the manufacturer’s recommendations and studies in the literature. The effects of sustainable cutting fluids and their parameters on machinability and power consumption were investigated through experiments. This study concluded that the use of nanofluid led to improvements in surface roughness, flank wear, and power consumption characteristics. It was determined that the flood environment is the most effective in reducing the cutting temperature. As a result, it is predicted that nanofluid cutting fluids can be used during machining. Full article
(This article belongs to the Special Issue Recent Advances in Surface Integrity with Machining and Milling)
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19 pages, 9470 KiB  
Article
Optimizing Machining Efficiency in High-Speed Milling of Super Duplex Stainless Steel with SiAlON Ceramic Inserts
by Monica Guimarães, Victor Saciotto, Qianxi He, Jose M. DePaiva, Anselmo Diniz and Stephen Veldhuis
Machines 2024, 12(5), 349; https://doi.org/10.3390/machines12050349 - 17 May 2024
Viewed by 1407
Abstract
Super duplex stainless steels (SDSSs) are widely utilized across industries owing to their remarkable mechanical properties and corrosion resistance. However, machining SDSS presents considerable challenges, particularly at high speeds. This study investigates the machinability of SDSS grade SAF 2507 (UNS S32750) under high-speed [...] Read more.
Super duplex stainless steels (SDSSs) are widely utilized across industries owing to their remarkable mechanical properties and corrosion resistance. However, machining SDSS presents considerable challenges, particularly at high speeds. This study investigates the machinability of SDSS grade SAF 2507 (UNS S32750) under high-speed milling conditions using SiAlON insert tools. Comprehensive analysis of key machinability indicators, including chip compression ratio, chip analysis, shear angle, tool wear, and friction conditions, reveals that lower cutting speeds optimize machining performance, reducing cutting forces and improving chip formation. Finite element analysis (FEA) corroborates the efficacy of lower speeds and moderate feed rates. Furthermore, insights into friction dynamics at the tool–chip interface are offered, alongside strategies for enhancing SDSS machining. This study revealed the critical impact of cutting speed on cutting forces, with a significant reduction in forces at cutting speeds of 950 and 1350 m/min, but a substantial increase at 1750 m/min, particularly when tool wear is severe. Furthermore, the combination of 950 and 1350 m/min cutting speeds with a 0.2 mm/tooth feed rate led to smoother chip surfaces and decreased friction coefficients, thus enhancing machining efficiency. The presence of stick–slip phenomena at 1750 m/min indicated thermoplastic instability. Optimizing machining parameters for super duplex stainless steel necessitates balancing material removal rate and surface integrity, as the latter plays an important role in ensuring long-term performance and reliability in critical applications. Full article
(This article belongs to the Special Issue Recent Advances in Surface Integrity with Machining and Milling)
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12 pages, 3507 KiB  
Article
An Investigation of Residual Stresses after the Turning of High-Tempered Bearing Steel
by Anna Mičietová, Mária Čilliková, Robert Čep, Branislav Mičieta, Juraj Uríček and Miroslav Neslušan
Machines 2024, 12(2), 139; https://doi.org/10.3390/machines12020139 - 17 Feb 2024
Cited by 1 | Viewed by 1274
Abstract
This study is focused on analysing residual stresses (RSs) after turning high-tempered bearing steel through the use of the X-ray diffraction (XRD) technique. Phase transformations expressed in terms of the near-surface white layer (WL) and the corresponding microhardness profiles are correlated with the [...] Read more.
This study is focused on analysing residual stresses (RSs) after turning high-tempered bearing steel through the use of the X-ray diffraction (XRD) technique. Phase transformations expressed in terms of the near-surface white layer (WL) and the corresponding microhardness profiles are correlated with the RSs as well as the depth of the RS profiles. Normal and shear components of RS and FWHM (full width at half maximum) of the diffraction peaks are analysed as a function of cutting insert flank wear as well as the cutting speed. It was found that the influence of tool wear prevails over cutting speed, RSs tend to shift into the compressive region with increasing tool flank wear, and the valuable shear components of RSs can be found in the near-surface region when the cutting inserts of lower flank wear are employed. The increasing flank wear also increases the depth in which the compressive RSs can be found. Furthermore, surface RSs are affected by the phase transformation process (formation of re-hardened WL) as well as the superimposing mechanical and thermal load. Full article
(This article belongs to the Special Issue Recent Advances in Surface Integrity with Machining and Milling)
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21 pages, 5596 KiB  
Article
Milling Force Modeling Methods for Slot Milling Cutters
by Mingzhou Wu, Guangpeng Zhang, Tianle Wang and Rui Wang
Machines 2023, 11(10), 922; https://doi.org/10.3390/machines11100922 - 22 Sep 2023
Viewed by 1465
Abstract
The slot milling cutter is primarily used for machining the tongue and groove of the steam turbine rotor, which is a critical operation in the manufacturing process of the steam turbine rotor. It is challenging to predict the milling force of a groove [...] Read more.
The slot milling cutter is primarily used for machining the tongue and groove of the steam turbine rotor, which is a critical operation in the manufacturing process of the steam turbine rotor. It is challenging to predict the milling force of a groove milling cutter due to variations in rake, rake angles and cutting speeds of the main cutting edge. Firstly, based on a limited amount of experimental data on turning, we have developed an equivalent turning force model that takes into account the impact of the rounded cutting edge radius, the tool’s tip radius and the feed rate on tool’s geometric angle. It provides a more accurate frontal angle for the identification method of the Johnson–Cook material constitutive equation. Secondly, the physical parameters, such as shear stress, shear strain and strain rate on the main shear plane, are calculated through the analysis of experimental data and application of the orthogonal cutting theory. Thirdly, the range of initial constitutive parameters of the material was determined through the split Hopkinson pressure bar (SHPB) test. The objective function was defined as the minimum error between the theoretical and experimental values. The optimal values of the Johnson–Cook constitutive equation parameters A, B, C, n and m are obtained through a global search using a genetic algorithm. Finally, the shear stress is determined by the governing equations of deformation, temperature and material. The axial force, torque and bending moment of each micro-segment are calculated and summed using the unit cutting force vector of each micro-segment. As a result, a milling force prediction model for slot milling cutters is established, and its validity is verified through experiments. Full article
(This article belongs to the Special Issue Recent Advances in Surface Integrity with Machining and Milling)
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