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Metals
Special Issues
Green Manufacturing for Metallic Materials
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Green Manufacturing for Metallic Materials

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (31 March 2024) | Viewed by 7299

Special Issue Editors

Dr. Fu-Chuan Hsu

E-Mail Website
Guest Editor
Metal Industries Research and Development Centre (MIRDC), Micro/Meso Mechanical Manufacturing R&D Department (M4 Dept.), Kaohsiung 81160, Taiwan
Interests: micro cutting; micro wire electrical discharge machining; micro electrical discharge machining; micro shot peening; micro blasting; green metal forming; hybrid manufacturing
Dr. Yixuan Feng

E-Mail Website
Guest Editor
Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332, USA
Interests: ultrasonic-vibration-assisted milling; laser-assisted milling
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The green advanced/hybrid manufacturing process has become increasingly important in industry due to carbon tax and a friendly environment. The surface quality of difficult-to-machine materials and metallic materials, such as Inconel, tungsten carbide, polycrystal diamond (PCD), cermet, ferrous and non-ferrous metals, is affected by the conditions of cutting tools, workpieces, process parameters, lubrication, machine performance, etc. Many green advanced/hybrid manufacturing processes have been developed in recent years to enhance the machinability of these materials. In this Special Issue, the research topics of interest include the experiment and simulation of green metal cutting/milling/forming/ultrasonic-vibration-assisted milling (USM)/laser-assisted milling (LAM)/minimum quantity lubrication (MQL)/electrical discharge machining (EDM)/wire electrical discharge machining (WEDM)/electrochemical machining (ECM)/ultrafast laser/micro particle bombarding (MPB) surface treatment, such as micro peening and micro blasting. All papers related to increasing the manufacturing efficiency of high-performance metallic materials with lower energy consumption and fossil lubrication via green advanced/hybrid manufacturing are welcome to this Special Issue.

Dr. Fu-Chuan Hsu
Dr. Yixuan Feng
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. Metals 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

  • green manufacturing (machining/forming/surface treatment)
  • hybrid manufacturing
  • ultrasonic-vibration-assisted milling (USM)
  • laser-assisted milling (LAM)
  • minimum quantity lubrication (MQL)
  • electrical discharge machining (EDM)
  • wire electrical discharge machining (WEDM)
  • electrochemical machining (ECM)
  • ultrafast laser
  • micro particle bombarding (MPB) treatment

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Published Papers (4 papers)

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Research

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14 pages, 4393 KiB  
Article
Effect of Minimum Quantity of Lubricant on Carbide Tools and Surface Integrity in the Machining of Titanium Aluminides
by Enrique García-Martínez, Valentín Miguel and Alberto Martínez-Martínez
Metals 2024, 14(4), 399; https://doi.org/10.3390/met14040399 - 28 Mar 2024
Viewed by 941
Abstract
Titanium aluminides are being explored as potential materials for the aeronautical sector. However, their application is limited by the high costs of processing and their difficulties in machining. This research evaluates the effectiveness of the minimum quantity lubrication technique (MQL) on the turning [...] Read more.
Titanium aluminides are being explored as potential materials for the aeronautical sector. However, their application is limited by the high costs of processing and their difficulties in machining. This research evaluates the effectiveness of the minimum quantity lubrication technique (MQL) on the turning process of Ti48Al2Cr2Nb aluminide in terms of tool wear, tool life, cutting forces, surface integrity, and temperature. It was found that MQL conditions can improve the process efficiency, reducing the thermally induced wear mechanisms and enlarging the tool life compared to dry machining. Furthermore, it allows the cutting speed to be incremented, leading to lower processing times. However, MQL seems to not be effective in the reduction of the strain-hardening effect near the machined surface and, although the number of microcracks is reduced, defect-free surfaces cannot be obtained. Moreover, similar microstructural alterations as for dry cutting were detected. The best cutting conditions in terms of surface quality were assessed using the central composite face (CCF) design and surface response methodology. Optimization of the surface roughness under industrially viable cutting conditions was achieved with an average surface roughness value, Ra, of 0.29 µm (feed rate of 0.05 mm/rev, a cutting speed of 54.6 m/min and a depth of cut of 0.125 mm). Full article
(This article belongs to the Special Issue Green Manufacturing for Metallic Materials)
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20 pages, 10022 KiB  
Article
Mechanical, Tribological, and Corrosive Properties of NbCrCx and NbCrCxNy Coatings with Various Nitrogen and Carbon Contents
by Yean-Liang Su, Sung-Mao Chiu, Wen-Hsien Kao, Hsiang-Chun Hsueh and Tsung-Yen Hsieh
Metals 2023, 13(8), 1488; https://doi.org/10.3390/met13081488 - 18 Aug 2023
Cited by 2 | Viewed by 1155
Abstract
CrC and NbC carbide coatings both have good mechanical properties, wear resistance, and corrosion resistance. The present study seeks to combine the two coating systems in order to further enhance their properties. NbCrCx and NbCrCxNy coatings (where x and [...] Read more.
CrC and NbC carbide coatings both have good mechanical properties, wear resistance, and corrosion resistance. The present study seeks to combine the two coating systems in order to further enhance their properties. NbCrCx and NbCrCxNy coatings (where x and y denote the atomic percentages of carbon and nitrogen, respectively) were deposited on SKH51 substrates using a radio-frequency unbalanced magnetron sputtering system. The mechanical, tribological, and corrosive properties of the coatings were investigated and compared. Among the NbCrCx coatings, the NbCrC61 coating showed high levels of hardness, excellent adhesion strength, and good wear resistance. Among the NbCrCxNy coatings, the NbCrC55N5 coating showed high adhesion strength and hardness and excellent tribological properties. However, for nitrogen contents greater than 16 at%, the adhesion strength was dramatically reduced, resulting in poor tribological performance. Among all of the coatings, the NbCrC49 coating showed the best corrosion resistance due to its enhanced crystallinity, high adhesion strength, moderate surface roughness, and high sp3 C-C bonding ratio. Full article
(This article belongs to the Special Issue Green Manufacturing for Metallic Materials)
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24 pages, 5742 KiB  
Article
A Novel Electrode Front-End Face Design to Improve Geometric Accuracy in Electrical Discharge Machining Process
by Shih-Ming Wang, Jin-Kai Peng, Hariyanto Gunawan, Ren-Qi Tu and Shean-Juinn Chiou
Metals 2023, 13(6), 1122; https://doi.org/10.3390/met13061122 - 15 Jun 2023
Cited by 2 | Viewed by 1472
Abstract
Electrical discharge machining (EDM) is one of the important machining processes to produce mold components. When using the EDM process, surface quality, processing time, accuracy, and electrode cost must be considered. The electrode wear is the main factor that causes error on the [...] Read more.
Electrical discharge machining (EDM) is one of the important machining processes to produce mold components. When using the EDM process, surface quality, processing time, accuracy, and electrode cost must be considered. The electrode wear is the main factor that causes error on the geometric accuracy, especially the workpiece corner. Therefore, this study proposes a novel electrode design to improve the geometric accuracy for the EDM process. Firstly, the effect of discharge current, electrode diameter, and depth of cut on the electrode wear and workpiece corner were investigated. Multiple regression and analysis of variant were used to analyze the experiment data. The electrode end-face design with compensation rule and algorithm was established based on the data analysis and error value. Furthermore, a compensated electrode end-face design system with human machine interface, which has a procedure guiding function, was developed. The system can design the electrode end-face for minimizing workpiece corner error and improve geometric accuracy. Finally, cutting experiments were conducted to verify the proposed method, and the results show that the proposed method can effectively enhance the geometric accuracy by around 22~37%. Full article
(This article belongs to the Special Issue Green Manufacturing for Metallic Materials)
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Review

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15 pages, 3267 KiB  
Review
Ultrasonic Assisted Machining Overview: Accessing Feasibility and Overcoming Challenges for Milling Applications
by Henrique Martins and Hélder Puga
Metals 2023, 13(5), 908; https://doi.org/10.3390/met13050908 - 7 May 2023
Cited by 4 | Viewed by 3062
Abstract
Machinability, along with its associated facets, is a critical parameter that ultimately determines the cost of machining. Its optimization, however, is inherently limited by the current technology. To surmount such limitations, novel alternative machining technologies, such as Ultrasonic Assisted Machining (UAM), have emerged. [...] Read more.
Machinability, along with its associated facets, is a critical parameter that ultimately determines the cost of machining. Its optimization, however, is inherently limited by the current technology. To surmount such limitations, novel alternative machining technologies, such as Ultrasonic Assisted Machining (UAM), have emerged. The present study introduces UAM, the technology’s underlying principles, and general considerations for vibration application (harmonic waves, eigenfrequencies, resonance). The influence of ultrasonic application on the key parameters of conventional machining processes is studied and relevant research data are presented to support UAM benefits. Following, a comprehensive kinematic examination of vibration application to the milling process is conducted, accounting for various possible vibration modes. A detailed analysis of the requisite system components and their technical specifications is presented, followed by identifying common issues within such systems. Solutions for the identified limitations are proposed, acting as design guidelines for future technological advancements. Finally, based on the conducted research, conclusions are drawn and future directions for UAM are suggested. Full article
(This article belongs to the Special Issue Green Manufacturing for Metallic Materials)
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