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Machines
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Recent Advances in Surface Integrity with Machining and Milling
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Recent Advances in Surface Integrity with Machining and Milling

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

Deadline for manuscript submissions: 30 September 2024 | Viewed by 2158

Special Issue Editor

Prof. Dr. Kazumasa Kawasaki

E-Mail Website
Guest Editor
Department of Technology and Engineering Management, Sanjo City University, 5002-5 Kamisugoro, Sanjo 955-0091, Japan
Interests: high-precision and high-performance power transmission devices; cutting of difficult-to-cut materials; design of mechanical elements; machining

Special Issue Information

Dear Colleagues,

The surface integrity with machining and milling has long been recognized as having a significant impact on product performance, longevity and reliability. The surface integrity covers various areas, such as surface roughness, surface topography, nano- or microstructure alterations, and residual stresses. In addition, it causes microstructural, mechanical and chemical effects. Therefore, recent advances in surface integrity will be able to be effectively utilized and optimized in manufacturing processes. This topic is important to study for the improvement of the efficiency of machines.

Prof. Dr. Kazumasa Kawasaki
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. 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

  • surface roughness
  • surface topography
  • residual stresses
  • milling
  • machining

Published Papers (2 papers)

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Research

12 pages, 3507 KiB  
Article
An Investigation of Residual Stresses after the Turning of High-Tempered Bearing Steel
by Anna Mičietová, Mária Čilliková, Robert Čep, Branislav Mičieta, Juraj Uríček and Miroslav Neslušan
Machines 2024, 12(2), 139; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12020139 - 17 Feb 2024
Viewed by 836
Abstract
This study is focused on analysing residual stresses (RSs) after turning high-tempered bearing steel through the use of the X-ray diffraction (XRD) technique. Phase transformations expressed in terms of the near-surface white layer (WL) and the corresponding microhardness profiles are correlated with the [...] Read more.
This study is focused on analysing residual stresses (RSs) after turning high-tempered bearing steel through the use of the X-ray diffraction (XRD) technique. Phase transformations expressed in terms of the near-surface white layer (WL) and the corresponding microhardness profiles are correlated with the RSs as well as the depth of the RS profiles. Normal and shear components of RS and FWHM (full width at half maximum) of the diffraction peaks are analysed as a function of cutting insert flank wear as well as the cutting speed. It was found that the influence of tool wear prevails over cutting speed, RSs tend to shift into the compressive region with increasing tool flank wear, and the valuable shear components of RSs can be found in the near-surface region when the cutting inserts of lower flank wear are employed. The increasing flank wear also increases the depth in which the compressive RSs can be found. Furthermore, surface RSs are affected by the phase transformation process (formation of re-hardened WL) as well as the superimposing mechanical and thermal load. Full article
(This article belongs to the Special Issue Recent Advances in Surface Integrity with Machining and Milling)
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21 pages, 5596 KiB  
Article
Milling Force Modeling Methods for Slot Milling Cutters
by Mingzhou Wu, Guangpeng Zhang, Tianle Wang and Rui Wang
Machines 2023, 11(10), 922; https://0-doi-org.brum.beds.ac.uk/10.3390/machines11100922 - 22 Sep 2023
Viewed by 903
Abstract
The slot milling cutter is primarily used for machining the tongue and groove of the steam turbine rotor, which is a critical operation in the manufacturing process of the steam turbine rotor. It is challenging to predict the milling force of a groove [...] Read more.
The slot milling cutter is primarily used for machining the tongue and groove of the steam turbine rotor, which is a critical operation in the manufacturing process of the steam turbine rotor. It is challenging to predict the milling force of a groove milling cutter due to variations in rake, rake angles and cutting speeds of the main cutting edge. Firstly, based on a limited amount of experimental data on turning, we have developed an equivalent turning force model that takes into account the impact of the rounded cutting edge radius, the tool’s tip radius and the feed rate on tool’s geometric angle. It provides a more accurate frontal angle for the identification method of the Johnson–Cook material constitutive equation. Secondly, the physical parameters, such as shear stress, shear strain and strain rate on the main shear plane, are calculated through the analysis of experimental data and application of the orthogonal cutting theory. Thirdly, the range of initial constitutive parameters of the material was determined through the split Hopkinson pressure bar (SHPB) test. The objective function was defined as the minimum error between the theoretical and experimental values. The optimal values of the Johnson–Cook constitutive equation parameters A, B, C, n and m are obtained through a global search using a genetic algorithm. Finally, the shear stress is determined by the governing equations of deformation, temperature and material. The axial force, torque and bending moment of each micro-segment are calculated and summed using the unit cutting force vector of each micro-segment. As a result, a milling force prediction model for slot milling cutters is established, and its validity is verified through experiments. Full article
(This article belongs to the Special Issue Recent Advances in Surface Integrity with Machining and Milling)
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