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Applied Sciences
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Advanced Manufacturing of Metals
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Advanced Manufacturing of Metals

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Applied Industrial Technologies".

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 20864

Special Issue Editor

Dr. Marco Sortino

E-Mail Website
Guest Editor
Department of Electrical, Managerial and Mechanical Engineering, University of Udine, Udine, Italy
Interests: rapid prototyping; disassembly; micromachining and molding of micro-components; monitoring and optimization of machining processes; modeling and dynamics of machining processes; intelligent machining systems and adaptive control; machinability of metallic materials; statistical techniques for process control; manufacturing of parts for biomedical application; laser welding and cutting

Special Issue Information

Dear Colleagues,

Advanced manufacturing of metals refers to the creation of metal structures by cutting, bending, and assembling processes. It is an additive manufacturing process involving the creation of machines, parts, and structures from various raw materials. Industrial production employs a multitude of value-added processes, including welding, cutting, forming, and machining. Welding is the main focus of steel fabrication, whereby formed and machined parts are assembled and tack-welded in place then rechecked for accuracy; cutting and burning are a variety of the tools used to cut raw material; forming converts flat sheet metal into 3D parts by applying force without adding or removing material; and machining is a specialized trade of removing material from a block of metal to make a desired shape. Fab shops generally have some machining capability and use metal lathes, mills, drills, and other portable machining tools. Most solid components are machined, for example, gears, bolts, screws, and nuts. Examples of standard metal fabrication materials are plate metal, formed and expanded metal, tube stock, welding wire/welding rod, and casting.

The aim of this Special Issue is to present the state-of-the-art research on various domains of expertise related to the Special Issue theme.

The following are some examples of the topics proposed for this Special Issue:

  • Additive manufacturing, 3D printing
  • Advanced robotics and other intelligent production systems
  • Principal machining processes: turning, drilling, and milling
  • New industrial platform technologies

Dr. Marco Sortino
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. Applied Sciences 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 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

  • milling
  • metal cutting
  • laser melting
  • additive manufacturing
  • 3D printing
  • mechanical processes
  • intelligent manufacturing

Published Papers (7 papers)

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Research

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14 pages, 4658 KiB  
Article
Design and Analysis for Hypoid Gears with Ease-Off Flank Modification
by Qin Wang, Jinke Jiang, Hua Chen, Junwei Tian, Yu Su and Junde Guo
Appl. Sci. 2022, 12(2), 822; https://0-doi-org.brum.beds.ac.uk/10.3390/app12020822 - 14 Jan 2022
Cited by 4 | Viewed by 1709
Abstract
An approach of ease-off flank modification for hypoid gears was proposed to improve the meshing performance of automobile drive axle. Firstly, a conjugate pinion matching with gear globally was developed based on gear meshing theory. Secondly, a modified pinion was represented by a [...] Read more.
An approach of ease-off flank modification for hypoid gears was proposed to improve the meshing performance of automobile drive axle. Firstly, a conjugate pinion matching with gear globally was developed based on gear meshing theory. Secondly, a modified pinion was represented by a sum of two vector functions determining the conjugate pinion and the normal ease-off deviations expressed by both predesigned transmission error function and tooth profile modification curves to change the initial contact clearance of the tooth. Thirdly, the best ease-off deviations were determined by optimizing the minimum amplitude of loaded transmission error (ALTE) based on tooth contact analysis (TCA) and loaded tooth contact analysis (LTCA). Finally, the results show that effective contact ratios (εe) are established by clearances both teeth space and of contact elliptical, and greatly affect ALTE. The εe is a variable value with increasing loads for the tooth with modification. ALTE decreases with increasing εe. After εe reaches the maximum, ALTE increases with increasing loads. The mismatch of the best ease-off tooth is minimal, which contributes to effective reduction in ALTE, thus significantly improving drive performance. Full article
(This article belongs to the Special Issue Advanced Manufacturing of Metals)
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20 pages, 47760 KiB  
Article
Sustainability-Based Analysis of Conventional to High-Speed Machining of Al 6061-T6 Alloy
by Salman Sagheer Warsi, Taiba Zahid, Hassan Elahi, Raja Awais Liaqait, Saira Bibi, Fouzia Gillani and Usman Ghafoor
Appl. Sci. 2021, 11(19), 9032; https://0-doi-org.brum.beds.ac.uk/10.3390/app11199032 - 28 Sep 2021
Cited by 5 | Viewed by 1923
Abstract
High-speed machining is considered to be a promising machining technique due to its advantages, such as high productivity and better product quality. With a paradigm shift towards sustainable machining practices, the energy consumption analysis of high-speed machining is also gaining ever-increasing importance. The [...] Read more.
High-speed machining is considered to be a promising machining technique due to its advantages, such as high productivity and better product quality. With a paradigm shift towards sustainable machining practices, the energy consumption analysis of high-speed machining is also gaining ever-increasing importance. The current article addresses this issue and presents a detailed analysis of specific cutting energy (SCE) consumption and product surface finish (Ra) during conventional to high-speed machining of Al 6061-T6. A Taguchi-based L16 orthogonal array experimental design was developed for the conventional to high-speed machining range of an Al 6061-T6 alloy. The analysis of the results revealed that SCE consumption and Ra improve when the cutting speed is increased from conventional to high-speed machining. In particular, SCE was observed to reduce linearly in conventional and transitional speed machining, whereas it followed a parabolic trend in high-speed machining. This parabolic trend indicates the existence of an optimal cutting speed that may lead to minimum SCE consumption. Chip morphology was performed to further investigate the parabolic trend of SCE in high-speed machining. Chip morphology revealed that the serration of chips initiates when the cutting speed is increased beyond 1750 m/min at a feed rate of 0.4 mm/rev. Full article
(This article belongs to the Special Issue Advanced Manufacturing of Metals)
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18 pages, 3296 KiB  
Article
Impacts of Traverse Speed and Material Thickness on Abrasive Waterjet Contour Cutting of Austenitic Stainless Steel AISI 304L
by Jennifer Milaor Llanto, Majid Tolouei-Rad, Ana Vafadar and Muhammad Aamir
Appl. Sci. 2021, 11(11), 4925; https://0-doi-org.brum.beds.ac.uk/10.3390/app11114925 - 27 May 2021
Cited by 11 | Viewed by 2552
Abstract
Abrasive water jet machining is a proficient alternative for cutting difficult-to-machine materials with complex geometries, such as austenitic stainless steel 304L (AISI304L). However, due to differences in machining responses for varied material conditions, the abrasive waterjet machining experiences challenges including kerf geometric inaccuracy [...] Read more.
Abrasive water jet machining is a proficient alternative for cutting difficult-to-machine materials with complex geometries, such as austenitic stainless steel 304L (AISI304L). However, due to differences in machining responses for varied material conditions, the abrasive waterjet machining experiences challenges including kerf geometric inaccuracy and low material removal rate. In this study, an abrasive waterjet machining is employed to perform contour cutting of different profiles to investigate the impacts of traverse speed and material thickness in achieving lower kerf taper angle and higher material removal rate. Based on experimental investigation, a trend of decreasing the level of traverse speed and material thickness that results in minimum kerf taper angle values of 0.825° for machining curvature profile and 0.916° for line profiles has been observed. In addition, higher traverse speed and material thickness achieved higher material removal rate in cutting different curvature radii and lengths in line profiles with obtained values of 769.50 mm3/min and 751.5 mm3/min, accordingly. The analysis of variance revealed that material thickness had a significant impact on kerf taper angle and material removal rate, contributing within the range of 69–91% and 62–69%, respectively. In contrast, traverse speed was the least factor measuring within the range of 5–18% for kerf taper angle and 27–36% for material removal rate. Full article
(This article belongs to the Special Issue Advanced Manufacturing of Metals)
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15 pages, 5923 KiB  
Article
Evaluation of the Surface Defects and Dimensional Tolerances in Multi-Hole Drilling of AA5083, AA6061, and AA2024
by Muhammad Aamir, Majid Tolouei-Rad, Khaled Giasin, Ana Vafadar, Ugur Koklu and William Keeble
Appl. Sci. 2021, 11(9), 4285; https://0-doi-org.brum.beds.ac.uk/10.3390/app11094285 - 10 May 2021
Cited by 8 | Viewed by 2004
Abstract
Drilling is one of the most performed machining operations for riveting and assembly operations in many industrial sectors. The accuracy of the drilled holes and their surface finish play a vital role in the longevity and performance of the machined components, which, in [...] Read more.
Drilling is one of the most performed machining operations for riveting and assembly operations in many industrial sectors. The accuracy of the drilled holes and their surface finish play a vital role in the longevity and performance of the machined components, which, in turn, increase productivity. Therefore, this study investigated the effect of the multi-spindle drilling process on dimensional hole tolerances, such as hole size, circularity, cylindricity, and perpendicularity. In addition, the surface defects formed in the holes were examined using scanning electron microscopy. Three aluminium alloys, AA2024, AA6061, and AA5083, which are commonly used in the aerospace, automotive, and marine sectors, were chosen as the study materials. The results showed that the holes drilled in AA2024 gave less circularity error, cylindricity error, and perpendicularity error. In the case of hole size, the holes drilled in AA6061 were less deviated from the nominal size following holes drilled in AA2024 and AA5083 alloys. Surface damage in the form of metal debris adhesion, smeared material, side flow, and feed marks was found on the inner hole surface. Holes drilled in AA5083 alloy had the worst surface finish and were the most oversized, which was associated with noticeable damage and deformations in their inner surface. The ANOVA results revealed that the spindle speed was more influential than feed and mainly affected the hole size and cylindricity errors. However, in the case of circularity error and perpendicularity error, drilling parameters were found to be insignificant. Full article
(This article belongs to the Special Issue Advanced Manufacturing of Metals)
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24 pages, 4730 KiB  
Article
Feed Rate Variation Strategy for Semi-Conical Shell Workpiece in Ball Head End Milling Process
by Peng Qin, Min Wang and Lele Sun
Appl. Sci. 2020, 10(24), 9135; https://0-doi-org.brum.beds.ac.uk/10.3390/app10249135 - 21 Dec 2020
Cited by 3 | Viewed by 1974
Abstract
The semi-conical shell workpiece is a special kind of thin-wall part that is commonly used in aerospace and mold industries. Due to the special stiffness distribution and weak rigidity for the area with a large radius, the machining quality of the semi-conical shell [...] Read more.
The semi-conical shell workpiece is a special kind of thin-wall part that is commonly used in aerospace and mold industries. Due to the special stiffness distribution and weak rigidity for the area with a large radius, the machining quality of the semi-conical shell is sensitive to both cutting force and vibration. Conventionally, constant conservative machining parameters are chosen to ensure the workpiece deformation and surface quality, which will reduce the machining efficiency. Based on the cutting force and vibration response simulation of the whole milling process. A feed rate variation strategy is proposed for the ball head end milling process of the semi-conical shell workpiece. The cutting force, dynamic performance and stability prediction are obtained considering the shape and boundary conditions of the workpiece and the contour tool path of the milling process. Variable feed rate is used in the milling simulation to find the harmony between machining quality and efficiency. User-defined vibration amplitude and another user-defined cutting force threshold are used to find the optimal feed rate for each simulation segment. Both continuous and discrete feed rate variation strategies are proposed, and the improved discrete feed rate variation is applied in the milling experiment. About 25% of the consumed time is saved with almost the same machining quality by the experimental results. Full article
(This article belongs to the Special Issue Advanced Manufacturing of Metals)
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11 pages, 4084 KiB  
Article
Evaluation of Tensile Shear Strength under Salt Spray Test on Dissimilar Metal Spot Welding of Aluminum Alloy and Galvannealed Steel Sheet
by Sung-Min Joo, Young-Gon Kim and Min-Suk Oh
Appl. Sci. 2020, 10(22), 8116; https://0-doi-org.brum.beds.ac.uk/10.3390/app10228116 - 16 Nov 2020
Cited by 1 | Viewed by 2511
Abstract
In order to reduce the weight of parts in the automobile and electronic industries, various research on dissimilar welding techniques of aluminum and steel is being carried out. Since dissimilar materials have different physical and electrochemical characteristics, joining through conventional fusion welding is [...] Read more.
In order to reduce the weight of parts in the automobile and electronic industries, various research on dissimilar welding techniques of aluminum and steel is being carried out. Since dissimilar materials have different physical and electrochemical characteristics, joining through conventional fusion welding is challenging, and there is a high probability of a decrease in strength of the welded joints. To solve this problem, a mechanical fastening method is mainly applied to join dissimilar parts with different material properties, but this process has disadvantages in terms of productivity improvement and cost reduction because additional consumables, such as rivets, are required. In this research, we investigated the optimization of the weld bonding conditions of joints using epoxy-based adhesive bonding and DeltaSpot welding for Al/Fe dissimilar materials. For each experimental condition, the corrosion resistance and tensile shear strength of the welded joints were evaluated according to salt spray test times of 0 h, 640 h, 1280 h, and 1920 h. As a whole, as the salt spray test time increased, the tensile shear strength of the welded joints decreased. It was confirmed that weld bonding, after manual polishing of the aluminum side, resulted in the highest average tensile shear strength of 5.88 kN at 1920 h, which was an increase compared with other conditions. Full article
(This article belongs to the Special Issue Advanced Manufacturing of Metals)
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Review

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24 pages, 4948 KiB  
Review
Recent Progress Trend on Abrasive Waterjet Cutting of Metallic Materials: A Review
by Jennifer Milaor Llanto, Majid Tolouei-Rad, Ana Vafadar and Muhammad Aamir
Appl. Sci. 2021, 11(8), 3344; https://0-doi-org.brum.beds.ac.uk/10.3390/app11083344 - 08 Apr 2021
Cited by 41 | Viewed by 7360
Abstract
Abrasive water jet machining has been extensively used for cutting various materials. In particular, it has been applied for difficult-to-cut materials, mostly metals, which are used in various manufacturing processes in the fabrication industry. Due to its vast applications, in-depth comprehension of the [...] Read more.
Abrasive water jet machining has been extensively used for cutting various materials. In particular, it has been applied for difficult-to-cut materials, mostly metals, which are used in various manufacturing processes in the fabrication industry. Due to its vast applications, in-depth comprehension of the systems behind its cutting process is required to determine its effective usage. This paper presents a review of the progress in the recent trends regarding abrasive waterjet cutting application to extend the understanding of the significance of cutting process parameters. This review aims to append a substantial understanding of the recent improvement of abrasive waterjet machine process applications, and its future research and development regarding precise cutting operations in metal fabrication sectors. To date, abrasive waterjet fundamental mechanisms, process parameter improvements and optimization reports have all been highlighted. This review can be a relevant reference for future researchers in investigating the precise machining of metallic materials or characteristic developments in the identification of the significant process parameters for achieving better results in abrasive waterjet cutting operations. Full article
(This article belongs to the Special Issue Advanced Manufacturing of Metals)
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