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Optimization and Simulation in Alloy Cutting Processes (Second Volume)
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Optimization and Simulation in Alloy Cutting Processes (Second Volume)

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: 20 June 2025 | Viewed by 11288

Special Issue Editors

Prof. Dr. Wojciech Zębala

E-Mail Website
Guest Editor
Department of Production Engineering, Cracow University of Technology, Cracow, Poland
Interests: Production engineering; construction and operation of machines; physical aspects of the cutting process; precision machining; cutting of difficult-to-cut materials; modeling and simulation of machining processes; additive manufacturing; numerical calculation methods (FEM); CNC machine tools; CAD/CAM systems; measurements of the geometric surface structure and modern manufacturing techniques (HSC, HPC, Hard machining, 3D printing)
Special Issues, Collections and Topics in MDPI journals
Dr. Emilia Franczyk

E-Mail Website
Guest Editor Assistant
Faculty of Mechanical Engineering, Cracow University of Technology, Cracow, Poland
Interests: machining and additive methods (SLM, DMLS, FDM); semi finished product processing; difficult-to-cut materials; design and utilization of machining tools

Special Issue Information

Dear Colleagues,

In today’s manufacturing environment, including machining processes like turning, drilling, or milling, many industrial factories automate the production processes thus increasing the production efficiency and dimensional accuracy of machine parts. The development of simulation models allows for quick visualization of the chip formation process in a wide range of machining parameters, the course of tool wear and many others phenomenon difficult to observe in real-time. Machining simulation is generally used to optimize cutting processes to improve workpiece quality and determine the correct machining parameters.

This Special Issue aims to present recent advances in the optimization of cutting processes for modern manufacturing engineering, especially CNC machining, application of modern tools for machining difficult-to-cut materials, modeling and computer simulation of machining, and analysis of physical phenomena existing in the decohesion zone of the machined material.

It is my pleasure to invite you to submit original, high-quality research papers, short communications and state-of-the-art reviews for this Special Issue

Prof. Dr. Wojciech Zębala
Guest Editor

Dr. Emilia Franczyk
Guest Editor Assistant

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. Materials is an international peer-reviewed open access semimonthly 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

  • simulation
  • optimization
  • manufacturing
  • machining
  • CNC machining
  • difficult-to-cut materials
  • CAD/CAM systems

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Published Papers (7 papers)

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Research

26 pages, 24144 KiB  
Article
Machining Characteristics During Short Hole Drilling of Titanium Alloy Ti10V2Fe3Al
by Michael Storchak
Materials 2024, 17(22), 5569; https://doi.org/10.3390/ma17225569 - 14 Nov 2024
Viewed by 325
Abstract
The single-phase titanium ß-alloy Ti10V2Fe3Al (Ti-1023) has been widely used in the aerospace industry due to its unique mechanical properties, which include high fatigue strength and fracture toughness, as well as high corrosion resistance. On the other hand, these unique properties significantly hinder [...] Read more.
The single-phase titanium ß-alloy Ti10V2Fe3Al (Ti-1023) has been widely used in the aerospace industry due to its unique mechanical properties, which include high fatigue strength and fracture toughness, as well as high corrosion resistance. On the other hand, these unique properties significantly hinder the cutting processes of this material, especially those characterized by a closed machining process area, such as drilling. This paper is devoted to the study of the short hole drilling process of the above-mentioned titanium alloy using direct measurements and numerical modeling. Measurements of the cutting force components in the drilling process and determination of the resultant cutting force and total cutting power were performed. The macro- and microstructure of chips generated during drilling were analyzed, and the dependence of the chip compression ratio and the distance between neighboring segments of serrated chips on cutting speed and drill feed was determined. Experimental studies were supplemented by determining the temperature on the lateral clearance face of the drill’s outer cutting insert in dependence on the cutting modes. For the modeling of the drilling process using the finite element model, the parameters of the triad of component submodels of the numerical model were determined: the machined material model, the model of contact interaction between the tool and the machined material, and the fracture model of the machined material. The determination of these parameters was performed through the DOE sensitivity analysis. The target values for performing this analysis were the total cutting power and the distance between neighboring chip segments. The maximum deviation between the simulated and experimentally determined values of the resulting cutting force is no more than 25%. At the same time, the maximum deviation between the measured values of the temperature on the lateral clearance face of the drill’s outer cutting insert and the corresponding simulated values is 26.1%. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes (Second Volume))
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13 pages, 3345 KiB  
Article
Impact of Cutting Data on Cutting Forces, Surface Roughness, and Chip Type in Order to Improve the Tool Operation Reliability in Sintered Cobalt Turning
by Emilia Franczyk and Wojciech Zębala
Materials 2024, 17(10), 2210; https://doi.org/10.3390/ma17102210 - 8 May 2024
Viewed by 905
Abstract
The authors present the results of laboratory tests analysing the impact of selected cutting data and tool geometry on surface quality, chip type and cutting forces in the process of orthogonal turning of sintered cobalt. The selected cutting data are cutting speed and [...] Read more.
The authors present the results of laboratory tests analysing the impact of selected cutting data and tool geometry on surface quality, chip type and cutting forces in the process of orthogonal turning of sintered cobalt. The selected cutting data are cutting speed and feed rate. During the experiments, the cutting speed was varied in the range of vc = 50–200 m/min and the feed rate in the range of f = 0.077–0.173 mm/rev. In order to measure and acquire cutting force values, a measuring setup was assembled. It consisted of a Kistler 2825A-02 piezoelectric dynamometer with a single-position tool holder, a Kistler 5070 signal amplifier and a PC with DynoWare software (Version 2825A, Kistler Group, Winterthur, Switzerland)). The measured surface quality parameters were Ra and Rz. The components of the cutting forces obtained in the experiment varied depending on the feed rate and cutting speed. The obtained test results will make it possible to determine the optimal parameters for machining and tool geometry in order to reduce the machine operating time and increase the life of the cutting insert during the turning of sintered cobalt, which will contribute to sustainable technology. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes (Second Volume))
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12 pages, 2479 KiB  
Article
Drilling Sequence Optimization Using Evolutionary Algorithms to Reduce Heat Accumulation for Femtosecond Laser Drilling with Multi-Spot Beam Profiles
by Christian Lutz, Jonas Helm, Katrin Tschirpke, Cemal Esen and Ralf Hellmann
Materials 2023, 16(17), 5775; https://doi.org/10.3390/ma16175775 - 23 Aug 2023
Cited by 4 | Viewed by 1362
Abstract
We report on laser drilling borehole arrays using ultrashort pulsed lasers with a particular focus on reducing the inadvertent heat accumulation across the workpiece by optimizing the drilling sequence. For the optimization, evolutionary algorithms are used and their results are verified by thermal [...] Read more.
We report on laser drilling borehole arrays using ultrashort pulsed lasers with a particular focus on reducing the inadvertent heat accumulation across the workpiece by optimizing the drilling sequence. For the optimization, evolutionary algorithms are used and their results are verified by thermal simulation using Comsol and experimentally evaluated using a thermal imaging camera. To enhance process efficiency in terms of boreholes drilled per second, multi-spot approaches are employed using a spatial light modulator. However, as higher temperatures occur across the workpiece when using simultaneous multi-spot drilling as compared to a single-spot process, a subtle spatial distribution and sequence of the multi-spot approach has to be selected in order to limit the resulting local heat input over the processing time. Different optimization approaches based on evolutionary algorithms aid to select those drilling sequences which allow for the combination of a high efficiency of multi-spot profiles, a low-generated process temperature and a high-component quality. In particular, using a 4 × 4 laser spot array allows for the drilling of 40,000 boreholes in less than 76 s (526 boreholes/s) with a reduced temperature increase by about 35%, as compared to a single spot process when employing an optimized drilling sequence. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes (Second Volume))
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18 pages, 6554 KiB  
Article
Analysis of Vibration, Deflection Angle and Surface Roughness in Water-Jet Cutting of AZ91D Magnesium Alloy and Simulation of Selected Surface Roughness Parameters Using ANN
by Katarzyna Biruk-Urban, Ireneusz Zagórski, Monika Kulisz and Michał Leleń
Materials 2023, 16(9), 3384; https://doi.org/10.3390/ma16093384 - 26 Apr 2023
Cited by 13 | Viewed by 1719
Abstract
The use of magnesium alloys in various industries and commerce is increasing due to their properties such as high strength and casting properties, high vibration damping capability, good shielding of electromagnetic radiation and high machinability. Conventional machining methods can, however, pose a risk [...] Read more.
The use of magnesium alloys in various industries and commerce is increasing due to their properties such as high strength and casting properties, high vibration damping capability, good shielding of electromagnetic radiation and high machinability. Conventional machining methods can, however, pose a risk of ignition. AWJM is a safe alternative to conventional machining, but the deflection and vibration of the water jet can affect surface quality. Therefore, the aim of this study was to investigate the effects of selected AWJM parameters on the surface quality and vibration of machined magnesium alloys. Jet deflection angle, surface roughness parameters and vibration during AWJM were investigated. The findings showed that higher skewness occurred at a lower abrasive flow rate, while higher average values of the Sku roughness parameter were obtained at ma = 8 g/s in the range of 60–140 mm/min. It was also observed that higher vibration values occurred at ma = 8 g/s. The input parameters for creating an artificial neural network (ANN) model used in this study were the cutting speed vf and the mass flow rate ma. The results of this study provided valuable insights into ways of ensuring a safe and efficient machining environment for magnesium alloys. The use of ANN modeling for predicting the vibration and surface roughness of AZ91D magnesium alloy after water-jet cutting could be an effective tool for optimizing AWJM parameters. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes (Second Volume))
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10 pages, 5210 KiB  
Article
Optimization of Titanium Alloy Drilling to Minimize the Secondary Burr after Deburring Process
by Emilia Franczyk and Wojciech Zębala
Materials 2022, 15(23), 8432; https://doi.org/10.3390/ma15238432 - 26 Nov 2022
Cited by 4 | Viewed by 1786
Abstract
The formation of burrs on the edges of machined surfaces is one of the inherent problems during machining. The burrs are formed both on the tool entry surface and exit surfaces. The paper proposes a modification of the drill involving an additional cutting [...] Read more.
The formation of burrs on the edges of machined surfaces is one of the inherent problems during machining. The burrs are formed both on the tool entry surface and exit surfaces. The paper proposes a modification of the drill involving an additional cutting insert located in the shank part. This innovative solution allowed the drill and deburring insert to be integrated, enabling both processes to be performed within one machining operation. The impact of the selected insert geometry and deburring process parameters on the size of burrs was determined during the experimental studies. Using the proposed deburring process for the Ti6Al4V titanium alloy, with appropriately chosen tool geometry and cutting parameters, reduces the secondary burr height by more than 90% compared to the original value. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes (Second Volume))
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17 pages, 3275 KiB  
Article
Multi-Objective Optimization of Process Parameters during Micro-Milling of Nickel-Based Alloy Inconel 718 Using Taguchi-Grey Relation Integrated Approach
by Muhammad Sheheryar, Muhammad Ali Khan, Syed Husain Imran Jaffery, Mansoor Alruqi, Rehan Khan, M. Nasir Bashir and Jana Petru
Materials 2022, 15(23), 8296; https://doi.org/10.3390/ma15238296 - 22 Nov 2022
Cited by 12 | Viewed by 2076
Abstract
This research investigates the machinability of Inconel 718 under conventional machining speeds using three different tool coatings in comparison with uncoated tool during milling operation. Cutting speed, feed rate and depth of cut were selected as variable machining parameters to analyze output responses [...] Read more.
This research investigates the machinability of Inconel 718 under conventional machining speeds using three different tool coatings in comparison with uncoated tool during milling operation. Cutting speed, feed rate and depth of cut were selected as variable machining parameters to analyze output responses including surface roughness, burr formation and tool wear. It was found that uncoated and AlTiN coated tools resulted in lower tool wear than nACo and TiSiN coated tools. On the other hand, TiSiN coated tools resulted in highest surface roughness and burr formation. Among the three machining parameters, feed was identified as the most influential parameter affecting burr formation. Grey relational analysis identified the most optimal experimental run with a speed of 14 m/min, feed of 1 μm/tooth, and depth of cut of 70 μm using an AlTiN coated tool. ANOVA of the regression model identified the tool coating parameter as most effective, with a contribution ratio of 41.64%, whereas cutting speed and depth of cut were found to have contribution ratios of 18.82% and 8.10%, respectively. Experimental run at response surface optimized conditions resulted in reduced surface roughness and tool wear by 18% and 20%, respectively. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes (Second Volume))
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14 pages, 1679 KiB  
Article
Statistical Analysis of Machining Parameters on Burr Formation, Surface Roughness and Energy Consumption during Milling of Aluminium Alloy Al 6061-T6
by Sajid Raza Zaidi, Najam Ul Qadir, Syed Husain Imran Jaffery, Muhammad Ali Khan, Mushtaq Khan and Jana Petru
Materials 2022, 15(22), 8065; https://doi.org/10.3390/ma15228065 - 15 Nov 2022
Cited by 11 | Viewed by 2376
Abstract
Due to the increasing demand for higher production rates in the manufacturing sector, there is a need to manufacture finished or near-finished parts. Burrs and surface roughness are the two most important indicators of the surface quality of any machined parts. In addition [...] Read more.
Due to the increasing demand for higher production rates in the manufacturing sector, there is a need to manufacture finished or near-finished parts. Burrs and surface roughness are the two most important indicators of the surface quality of any machined parts. In addition to this, there is a constant need to reduce energy consumption during the machining operation in order to reduce the carbon footprint. Milling is one of the most extensively used cutting processes in the manufacturing industry. This research was conducted to investigate the effect of machining parameters on surface roughness, burr width, and specific energy consumption. In the present research, the machining parameters were varied using the Taguchi L9 array design of experiments, and their influence on the response parameters, including specific cutting energy, surface finish, and burr width, was ascertained. The response trends of burr width, energy consumption, and surface roughness with respect to the input parameters were analyzed using the main effect plots. Analysis of variance indicated that the cutting speed has contribution ratios of 55% and 47.98% of the specific cutting energy and burr width on the down-milling side, respectively. On the other hand, the number of inserts was found to be the influential member, with contribution ratios of 68.74% and 35% of the surface roughness and burr width on the up-milling side. The validation of the current design of the experiments was carried out using confirmatory tests in the best and worst conditions of the output parameters. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes (Second Volume))
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