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Non-conventional Machining: Materials and Processes
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Non-conventional Machining: Materials and Processes

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 October 2025 | Viewed by 2323

Special Issue Editors

Dr. Magdalena Zawada-Michałowska

E-Mail Website
Guest Editor
Faculty of Mechanical Engineering, Lublin University of Technology, ul. Nadbystrzycka 38D, 20-618 Lublin, Poland
Interests: thin-walled element; strain; residual stress; milling; light metal alloys; coordinate metrology
Special Issues, Collections and Topics in MDPI journals
Dr. Paweł Pieśko

E-Mail Website
Guest Editor
Faculty of Mechanical Engineering, Lublin University of Technology, ul. Nadbystrzycka 38D, 20-618 Lublin, Poland
Interests: machining; milling; high speed machining; thin-walled element; light metal alloys; CAD/CAM
Prof. Dr. Stanislaw Legutko

E-Mail Website
Guest Editor
Faculty of Mechanical Engineering, Poznan University of Technology, 60-965 Poznan, Poland
Interests: additive manufacturing; precision machining; surface integrity
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue, titled “Non-Conventional Machining: Materials and Processes", will mainly focus on ensuring a deep understanding of the development needs of the manufacturing industry and an accurate grasp of future development trends. Through continuous exploration and innovation, non-traditional processing methods will play an increasingly important role in the field of material processing, providing strong support for the sustainable development of the manufacturing industry.

Taking into account the current directions of manufacturing development, Industry 4.0 should, in particular, be provided for, as should the tendency to boost the efficiency and effectiveness of machining, thus reducing production costs and the harmful impact on the environment.

This Special Issue will present novel scientific papers related to non-conventional machining, both in terms of the materials used and the process itself, as well as coordinate metrology.

Research areas may include (but are not limited to) the following:

  • Conventional and non-conventional machining;
  • Recent developments in machining;
  • Physical phenomena in machining process;
  • Cutting tool performance;
  • Manufacturing of thin-walled elements;
  • Trends in coordinate metrology;
  • Machining of engineering materials;
  • Machining of difficult-to-cut materials;
  • Machining efficiency and quality after cutting;
  • Optimization of the machining process;
  • Experimental and simulation research in the field of machining;
  • High-speed machining: high-speed cutting, and high-performance cutting;
  • Recent developments in additive manufacturing;
  • Assessment of machinability indicators;
  • Application of CAD/CAM in machining;
  • Development in Industry 4.0.

Dr. Magdalena Zawada-Michałowska
Dr. Paweł Pieśko
Prof. Dr. Stanislaw Legutko
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. 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

  • machining
  • high-speed machining
  • CNC machining
  • additive manufacturing
  • non-conventional manufacturing
  • engineering materials
  • CAD/CAM
  • machinability indicators
  • cutting tools
  • coordinate metrology

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

Published Papers (3 papers)

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Research

24 pages, 13675 KiB  
Article
Low-Waste Technology for High-Precision Connecting Rod Forging Manufacturing
by Łukasz Dudkiewicz and Marek Hawryluk
Materials 2025, 18(2), 443; https://doi.org/10.3390/ma18020443 - 18 Jan 2025
Viewed by 700
Abstract
This study refers to the application of an advanced tool in the form of numerical modelling in order to develop a low-waste hot die forging technology to produce a connecting rod forging. The technology aims at ensuring a limited amount of the charge [...] Read more.
This study refers to the application of an advanced tool in the form of numerical modelling in order to develop a low-waste hot die forging technology to produce a connecting rod forging. The technology aims at ensuring a limited amount of the charge material is necessary to produce one forging, as well as minimizing forging forces, and thus the electric energy consumption. The study includes a verification of the current production technology, which constituted the basis for the construction and development of a numerical model. A new construction of the forging tools was developed, with an additional pre-roughing pass (0X). The new process consists of die forging in the pre-roughing pass (0X), the roughing pass (1X) and the finishing impression (2X). Numerical modelling was subsequently conducted with the use of the Forge 3.0 NxT software. A detailed analysis was conducted on the accuracy of the tool impression filling (including the pre-roughing pass) by the deformed material, the distribution of temperatures for the forgings and the plastic deformations, as well as the courses of forging forces and energy. The results were verified under industrial conditions and compared with the forgings obtained in the previous technology (a roughing pass and a finishing impression). As a result of introducing the pre-roughing pass 0X, the forces were distributed between three impressions, including the especially developed pre-roughing pass. It was confirmed that the abovementioned changes in terms of forging tool construction had a positive effect on relieving the roughing pass and the finishing impression as well as limiting the charge material, and they also lowered the process energy consumption by 10%. This study also validated the relevance of using FE modelling to verify processes under virtual conditions before being implemented under industrial conditions. Therefore, the proposed approach based on multi-variant numerical simulations can be successfully used to improve other manufacturing processes in terms of reducing energy and material consumption and increasing tool service life. Full article
(This article belongs to the Special Issue Non-conventional Machining: Materials and Processes)
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15 pages, 5821 KiB  
Article
On the Use of Cyclic Cryogenic Treatment to Improve the Properties of High-Speed Steel
by Paweł Pieśko, Jarosław Korpysa and Magdalena Zawada-Michałowska
Materials 2024, 17(23), 5998; https://doi.org/10.3390/ma17235998 - 7 Dec 2024
Viewed by 651
Abstract
Cryogenic treatment is a process of controlled gradual cooling of the workpiece to a temperature ranging from −60 °C to even below −190 °C, holding the workpiece at this temperature and then slowly reheating it to ambient temperature. According to the current state [...] Read more.
Cryogenic treatment is a process of controlled gradual cooling of the workpiece to a temperature ranging from −60 °C to even below −190 °C, holding the workpiece at this temperature and then slowly reheating it to ambient temperature. According to the current state of knowledge, the purpose of cryogenic treatment is to reduce the concentration of retained austenite by transforming it into hard martensite under low-temperature treatment. The retained austenite reduction in steels results in improved hardness, impact strength, and wear resistance. This study involved conducting comparative tests of the hardness, tensile strength, and impact strength of high-speed steel samples with and without cryogenic treatment, which made it possible to determine the effect of cyclic cryogenic treatment on the properties of this steel. In addition to that, machining tests were conducted to assess the life of a cutting tool edge made from both cryogenic-treated and non-cryogenic-treated high-speed steel. Also, the austenite concentration in the samples was measured by X-ray diffraction. Obtained results confirmed that the cyclic cryogenic treatment enhanced all tested properties of the high-speed steel. Full article
(This article belongs to the Special Issue Non-conventional Machining: Materials and Processes)
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16 pages, 7454 KiB  
Article
Dimensional Accuracy After Precision Milling of Magnesium Alloys Using Coated and Uncoated Cutting Tools
by Jarosław Korpysa and Witold Habrat
Materials 2024, 17(22), 5578; https://doi.org/10.3390/ma17225578 - 15 Nov 2024
Viewed by 600
Abstract
Magnesium alloys are an important group of materials that are used in many industries, primarily due to their low weight. Constantly increasing quality requirements make it necessary to improve the accuracy of manufactured products. In this study, the precision milling process for AZ91D [...] Read more.
Magnesium alloys are an important group of materials that are used in many industries, primarily due to their low weight. Constantly increasing quality requirements make it necessary to improve the accuracy of manufactured products. In this study, the precision milling process for AZ91D and AZ31B magnesium alloys was investigated, and the results obtained with uncoated and TiB2-coated end mills were compared. The impact of variable cutting parameters was also investigated. Specifically, the study focused on the dimensional accuracy of the machined parts. The results showed that even though the dimensional accuracy obtained in milling both magnesium alloys was comparable, it was higher in the case of the AZ31B alloy by up to 22%. The study also demonstrated that the use of the TiB2 coating did not have the desired effect and that higher dimensional accuracy up to 27% was obtained with the uncoated tool. Full article
(This article belongs to the Special Issue Non-conventional Machining: Materials and Processes)
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