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Advances and Trends in Non-conventional, Abrasive and Precision Machining
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Advances and Trends in Non-conventional, Abrasive and Precision Machining

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

Deadline for manuscript submissions: closed (15 December 2020) | Viewed by 30825

Printed Edition Available!
A printed edition of this Special Issue is available here.

Special Issue Editors

Prof. Dr. Mariusz Deja

E-Mail Website
Guest Editor
Department of Manufacturing and Production Engineering, Faculty of Mechanical Engineering, Gdańsk University of Technology, 80-233 Gdańsk, Poland
Interests: adaptive and dynamic process planning; modelling and developing new tools for abrasive processes; design for additive manufacturing (DFAM)
Special Issues, Collections and Topics in MDPI journals
Dr. Angelos P. Markopoulos

E-Mail Website
Guest Editor
Section of Manufacturing Technology, School of Mechanical Engineering, National Technical University of Athens, 15780 Athens, Greece
Interests: nanotechnology; artificial intelligence and neural networks; precision and ultraprecision machining; nanomaterials; non-conventional machining; molecular dynamics
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The modern highly competitive industrial environment demands machining and production processes resulting in exceptional quality and precision. The general trend to design and manufacture more complicated mechanical components, along with the rapidly moving forward material science, raise the need to incorporate and develop new machining techniques in the manufacturing process. Nonconventional machining processes differ from conventional ones, as they utilize alternative types of energy, such as thermal, electrical, and chemical, to form or to remove material. Commonly, the energy source has high power density, while the process features prodigious accuracy, and the capability to produce and handle demanding shapes and geometries. Examples of nonconventional machining processes are electrical discharge machining (EDM), electrochemical machining (ECM), laser processing, and laser-assisted machining. Abrasive processes like grinding, lapping, polishing, and superfinishing are constantly developing and allow for obtaining a fine surface finish along with high efficiency.   

There is an increased scientific and commercial interest in in-depth understanding, and further development of the aforementioned nonconventional and precision machining processes. Research is moving forward through experimental studies, as well in the field of modeling and simulation, exploiting the increased available computational power. Multiphysics and multidisciplinary and multiscale modeling are powerful tools in the effort to optimize existing nonconventional precision machining processes, as well to develop novel ones. As their wider use by the industry swiftly grows, research has to be focused on them, not only due to the academic and scientific interest, but also for the possible financial gain.

This Special Issue aims at attracting researchers to present recent advances and technologies in the aforementioned fields, indicating the future trends for nonconventional precision machining processes.

D.Sc., Ph.D. Mech. Eng. Prof. Mariusz Deja
Prof. Angelos P. Markopoulos
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. 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

  • Laser processing/laser-assisted machining
  • High-density power machining
  • Electrodischarge machining
  • Electrochemical machining
  • Abrasive processes
  • Lapping/polishing/superfinishing
  • Ultrasonic machining
  • Water jet machining/abrasive water jet machining
  • Burnishing
  • Other nonconventional machining
  • Precision machining
  • Micro- and nanomachining
  • Machine tools
  • Modeling and simulation
  • Surface quality and integrity
  • Manufacturing systems
  • Nanomaterials

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Published Papers (9 papers)

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Editorial

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3 pages, 154 KiB  
Editorial
Advances and Trends in Non-Conventional, Abrasive and Precision Machining
by Mariusz Deja and Angelos P. Markopoulos
Machines 2021, 9(2), 37; https://doi.org/10.3390/machines9020037 - 8 Feb 2021
Cited by 2 | Viewed by 2497
Abstract
n/a Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining)

Research

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15 pages, 37237 KiB  
Article
Surface Finishing of Zirconium Dioxide with Abrasive Brushing Tools
by Eckart Uhlmann and Anton Hoyer
Machines 2020, 8(4), 89; https://doi.org/10.3390/machines8040089 - 21 Dec 2020
Cited by 10 | Viewed by 2754
Abstract
Brushing with bonded abrasives is a finishing process which can be used for the surface improvement of various materials. Since the machining mechanisms of abrasive brushing processes are still largely unknown and little predating research was done on brushing ceramic workpieces, within the [...] Read more.
Brushing with bonded abrasives is a finishing process which can be used for the surface improvement of various materials. Since the machining mechanisms of abrasive brushing processes are still largely unknown and little predating research was done on brushing ceramic workpieces, within the scope of this work technological investigations were carried out on planar workpieces of MgO-PSZ (zirconium dioxide, ZrO2) using brushing tools with bonded grains of polycrystalline diamond. The primary goal was the reduction of grinding-related surface defects under the preservation of surface roughness valleys and workpiece form. Based on microscopy and topography measurements, the grain size sg and the brushing velocity vb were found to have a considerable influence on the processing result. Furthermore, excessive tool wear was observed while brushing ceramics. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining)
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29 pages, 12135 KiB  
Article
The Proposition of an Automated Honing Cell with Advanced Monitoring
by Adam Barylski and Piotr Sender
Machines 2020, 8(4), 70; https://doi.org/10.3390/machines8040070 - 28 Oct 2020
Cited by 5 | Viewed by 4010
Abstract
Honing of holes allows for small shape deviation and a low value of a roughness profile parameter, e.g., Ra parameter. The honing process heats the workpiece and raises its temperature. The increase in temperature causes thermal deformations of the honed holes. The article [...] Read more.
Honing of holes allows for small shape deviation and a low value of a roughness profile parameter, e.g., Ra parameter. The honing process heats the workpiece and raises its temperature. The increase in temperature causes thermal deformations of the honed holes. The article proposes the construction of a honing cell, containing in addition to CNC honing machine: thermographic camera, sound intensity meter, and software for collecting and analyzing data received during machining. It was proposed that the level of sound intensity obtained during honing could be monitored continuously and that the images from a thermographic camera could be analyzed on-line. These analyses would be aimed at supervising honing along with the on-line correction of machining parameters. In addition to the oil cooler, the machining cell may have an automatic selection of the grain trajectory shape, with specified value of the radii of curvature of the abrasive grain trajectories, according to the wall thickness of the honed workpiece, which will result in reducing the temperature generated during honing. Automated honing cell can mostly increase honing process efficiency. Simulations in FlexSim showed the possibility of increasing the efficiency of the honing process more than 20 times. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining)
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21 pages, 35678 KiB  
Article
Analysis of the Possibility of Using Wavelet Transform to Assess the Condition of the Surface Layer of Elements with Flat-Top Structures
by Paweł Karolczak, Maciej Kowalski and Magdalena Wiśniewska
Machines 2020, 8(4), 65; https://doi.org/10.3390/machines8040065 - 22 Oct 2020
Cited by 9 | Viewed by 2551
Abstract
The paper focused on a topic related to the possibilities of using wavelet analysis to evaluate the changes in the geometrical structures of the surfaces arising during the honing process with whetstones with variable granularity. The cylinder liners of the combustion engine are [...] Read more.
The paper focused on a topic related to the possibilities of using wavelet analysis to evaluate the changes in the geometrical structures of the surfaces arising during the honing process with whetstones with variable granularity. The cylinder liners of the combustion engine are machined elements. The basics of the wavelet analysis and the differences between filtering with standardized filters (e.g., Gauss filter), Fourier analysis, and the analysis of the results obtained when measuring the surface roughness with other wavelets were described. Trials of honing four cylinder liners were carried out. Roughness measurements of 3D spatial structures of the prepared liners were made. The principle of selecting wavelets for roughness assessment of structures with cross-hatch pattern was described. Roughness structures generated on the honed surfaces of cylinder liners were assessed using Gaussian filtration and Morlet, Daubechies Db6, and Mexican hat wavelets. In order to demonstrate the differences generated when the Gaussian filtration and selected wavelets were used on surface structures, the surfaces obtained with the use of these filtering tools were subtracted from each other, which allowed obtaining information about the changes occurring on the assessed surfaces, which were generated after the use of various filtering tools. For the assessed surfaces, during the subtraction operation, the mean square error was calculated, informing about the degree of similarity of both compared surfaces. The result of the work carried out is the creation of basic recommendations for the selection of wavelets when assessing honed surfaces with different degrees of regularity of the traces generated on them. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining)
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17 pages, 5257 KiB  
Article
The Possibilities of Improving the Fatigue Durability of the Ship Propeller Shaft by Burnishing Process
by Stefan Dzionk, Włodzimierz Przybylski and Bogdan Ścibiorski
Machines 2020, 8(4), 63; https://doi.org/10.3390/machines8040063 - 18 Oct 2020
Cited by 11 | Viewed by 4294
Abstract
Heavily loaded structural elements operating in a corrosive environment are usually quickly destroyed. An example of such an element is a ship propeller operating in a seawater environment. This research presents a fatigue resistance test performed on elements operating in seawater. Different processing [...] Read more.
Heavily loaded structural elements operating in a corrosive environment are usually quickly destroyed. An example of such an element is a ship propeller operating in a seawater environment. This research presents a fatigue resistance test performed on elements operating in seawater. Different processing parameters applied on the samples in particular were compared with the specimens whose surface had been burnished differently and they were compared to specimens with a grinded surface. The research shows that the structural elements whose surface has been burnished can have up to 30% higher fatigue strength in a seawater environment than the elements whose surface has been grinded. During burnishing, an important feature of the process is the degree of cold rolling of the material. The resistance of the component to fatigue loads increases only to a certain level with increasing the degree of the cold rolling. Further increasing the degree of cold rolling reduces the fatigue strength. Introducing additional stresses in the components (e.g., assembly stresses) reduces the fatigue strength of this component in operation and these additional stresses should be accounted for while planning the degree of the cold rolling value. A device that allows for simultaneous turning and shaft burnishing with high slenderness is presented in the appendix of this article. This device can be connected to the computerized numerical control system and executed automatic process according to the machining program; this solution reduces the number of operations and cost in the process. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining)
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11 pages, 3855 KiB  
Article
Tool Wear Prediction in Single-Sided Lapping Process
by Norbert Piotrowski
Machines 2020, 8(4), 59; https://doi.org/10.3390/machines8040059 - 25 Sep 2020
Cited by 12 | Viewed by 2756
Abstract
Single-sided lapping is one of the most effective planarization technologies. The process has relatively complex kinematics and it is determined by a number of inputs parameters. It has been noted that prediction of the tool wear during the process is critical for product [...] Read more.
Single-sided lapping is one of the most effective planarization technologies. The process has relatively complex kinematics and it is determined by a number of inputs parameters. It has been noted that prediction of the tool wear during the process is critical for product quality control. To determine the profile wear of the lapping plate, a computer model which simulates abrasive grains trajectories was developed in MATLAB. Moreover, a data-driven technique was investigated to indicate the relationship between the tool wear uniformity and lapping parameters such as the position of conditioning rings and rotational speed of the lapping plate and conditioning rings. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining)
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18 pages, 13110 KiB  
Article
Studying the Effect of Working Conditions on WEDM Machining Performance of Super Alloy Inconel 617
by Stefan Dzionk and Mieczysław S. Siemiątkowski
Machines 2020, 8(3), 54; https://doi.org/10.3390/machines8030054 - 9 Sep 2020
Cited by 23 | Viewed by 3714
Abstract
Wire electrical discharge machining (WEDM) has been, for many years, a precise and efficient non-conventional manufacturing solution in various industrial applications, mostly involving the use of hard-to-machine materials like, among others, the Inconel super alloys. The focus of the present study is on [...] Read more.
Wire electrical discharge machining (WEDM) has been, for many years, a precise and efficient non-conventional manufacturing solution in various industrial applications, mostly involving the use of hard-to-machine materials like, among others, the Inconel super alloys. The focus of the present study is on exploring the effect of selected control parameters, including pulse duration, pulse-off time and the dielectric flow pressure on the WEDM process performance characteristics of Inconel 617 material, such as: volumetric material removal rate (MRR), the dimensional accuracy of cutting (reflected by the kerf width) and surface roughness (SR). The research experiment has been designed and carried out using the response surface methodology (RSM) accordingly with the Box–Behnken design scheme. The results of experiments derived in the form of a fitted regression model have been subjected to the analysis of variance (ANOVA) tests. Thus, the variable process parameters and the relevant interactions between them, characterized by a significant influence on the values of the derived output responses, could be explicitly determined. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining)
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13 pages, 2653 KiB  
Article
Experimental Study on the Influence of Machining Conditions on the Quality of Electrical Discharge Machined Surfaces of aluminum alloy Al5052
by Angelos P. Markopoulos, Emmanouil-Lazaros Papazoglou and Panagiotis Karmiris-Obratański
Machines 2020, 8(1), 12; https://doi.org/10.3390/machines8010012 - 2 Mar 2020
Cited by 26 | Viewed by 3680
Abstract
Although electrical discharge machining (EDM) is one of the first established non-conventional machining processes, it still finds many applications in the modern industry, due to its capability of machining any electrical conductive material in complex geometries with high dimensional accuracy. The current study [...] Read more.
Although electrical discharge machining (EDM) is one of the first established non-conventional machining processes, it still finds many applications in the modern industry, due to its capability of machining any electrical conductive material in complex geometries with high dimensional accuracy. The current study presents an experimental investigation of ED machining aluminum alloy Al5052. A full-scale experimental work was carried out, with the pulse current and pulse-on time being the varying machining parameters. The polishing and etching of the perpendicular plane of the machined surfaces was followed by observations and measurements in optical microscope. The material removal rate (MRR), the surface roughness (SR), the average white layer thickness (AWLT), and the heat affected zone (HAZ) micro-hardness were calculated. Through znalysis of variance (ANOVA), conclusions were drawn about the influence of machining conditions on the EDM performances. Finally, semi empirical correlations of MRR and AWLT with the machining parameters were calculated and proposed. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining)
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Other

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10 pages, 7509 KiB  
Letter
Surface Texture after Turning for Various Workpiece Rigidities
by Michal Dobrzynski and Karolina Mietka
Machines 2021, 9(1), 9; https://doi.org/10.3390/machines9010009 - 12 Jan 2021
Cited by 11 | Viewed by 2377
Abstract
In the paper, we present an analysis of the surface texture of turned parts with L/D (length/diameter) ratios of 6 and 12 and various rigidity values. The studies were carried out on samples made of S355JR steel and AISI 304 stainless steel. A [...] Read more.
In the paper, we present an analysis of the surface texture of turned parts with L/D (length/diameter) ratios of 6 and 12 and various rigidity values. The studies were carried out on samples made of S355JR steel and AISI 304 stainless steel. A detailed analysis of 2D surface profiles was carried out by using a large number of parameters that allowed us to distinguish significant differences in the surface microgeometry, which confirmed that determining surface characteristics from one height parameter (Ra—arithmetical mean height) is far from sufficient. The obtained results indicate significantly better roughness and waviness values of the AISI 304 steel surfaces in terms of its size, periodicity, and regularity. Therefore, the turning process of AISI 304 shafts with low rigidity allows one to be able to achieve better quality texture and have a positive effect on the general properties of a workpiece. In all tested samples, surface irregularities decreased along with the distance from the tailstock. The shafts with an L/D ratio of 12 had worse surfaces in the first two sections due to lower rigidity. The results received close to the three-jaw chuck, regardless of the L/D ratio and material type, demonstrated similar waviness and roughness parameters and profiles. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining)
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