Advances and Trends in Non-conventional, Abrasive and Precision Machining 2021

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

Deadline for manuscript submissions: closed (30 April 2022) | Viewed by 31048

Special Issue Editors

Department of Manufacturing and Production Engineering, Faculty of Mechanical Engineering, Gdańsk University of Technology, 80-233 Gdańsk, Poland
Interests: adaptive and dynamic process planning; modelling and developing new tools for abrasive processes; design for additive manufacturing DFAM
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The modern highly competitive industrial environment demands machining and production processes resulting in exceptional quality and precision. The general trend to design and manufacture more complicated mechanical components, along with the rapidly moving forward material science, raise the need to incorporate and develop new machining techniques in the manufacturing process. Nonconventional machining processes differ from conventional ones, as they utilize alternative types of energy, such as thermal, electrical, and chemical, to form or to remove material. Commonly, the energy source has high power density, while the process features prodigious accuracy, and the capability to produce and handle demanding shapes and geometries. Examples of nonconventional machining processes are electrical discharge machining (EDM), electrochemical machining (ECM), laser processing, and laser-assisted machining. Abrasive processes like grinding, lapping, polishing, and superfinishing are constantly developing and allow for obtaining a fine surface finish along with high efficiency.   

There is an increased scientific and commercial interest in in-depth understanding, and further development of the aforementioned nonconventional and precision machining processes. Research is moving forward through experimental studies, as well in the field of modeling and simulation, exploiting the increased available computational power. Multiphysics and multidisciplinary and multiscale modeling are powerful tools in the effort to optimize existing nonconventional precision machining processes, as well to develop novel ones. As their wider use by the industry swiftly grows, research has to be focused on them, not only due to the academic and scientific interest, but also for the possible financial gain.

This Special Issue aims at attracting researchers to present recent advances and technologies in the aforementioned fields, indicating the future trends for nonconventional precision machining processes.

Prof. Dr. Mariusz Deja
Prof. Dr. Angelos P. Markopoulos
Guest Editors

Manuscript Submission Information

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Keywords

  • Laser processing/laser-assisted machining
  • High-density power machining
  • Electrodischarge machining
  • Electrochemical machining
  • Abrasive processes
  • Lapping/polishing/superfinishing
  • Ultrasonic machining
  • Water jet machining/abrasive water jet machining
  • Burnishing
  • Other nonconventional machining
  • Precision machining
  • Micro- and nanomachining
  • Machine tools
  • Modeling and simulation
  • Surface quality and integrity
  • Manufacturing systems
  • Nanomaterials

Published Papers (12 papers)

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Editorial

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5 pages, 175 KiB  
Editorial
Advances and Trends in Non-Conventional, Abrasive and Precision Machining 2021
by Mariusz Deja and Angelos P. Markopoulos
Machines 2024, 12(2), 138; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12020138 - 17 Feb 2024
Viewed by 728
Abstract
Advances and Trends in Non-conventional, Abrasive and Precision Machining 2021 [...] Full article

Research

Jump to: Editorial

12 pages, 3278 KiB  
Article
Multi-Objective Optimization of Material Removal Rate and Tool Wear in Rough Honing Processes
by Irene Buj-Corral and Maurici Sivatte-Adroer
Machines 2022, 10(2), 83; https://0-doi-org.brum.beds.ac.uk/10.3390/machines10020083 - 24 Jan 2022
Cited by 5 | Viewed by 2352
Abstract
This study focuses on obtaining regression models for material removal rate and tool wear in rough honing processes. For this purpose, experimental tests were carried out according to a central composite design of experiments. Five different parameters were varied: grain size or particle [...] Read more.
This study focuses on obtaining regression models for material removal rate and tool wear in rough honing processes. For this purpose, experimental tests were carried out according to a central composite design of experiments. Five different parameters were varied: grain size or particle size of abrasive, density of abrasive or abrasive concentration, pressure of the stones against the cylinder internal surface, tangential speed (in this case, corresponding to the rotation speed of the cylinder), and linear speed of the honing head. In addition, multi-objective optimization was carried out with the aim of maximizing the material removal rate and minimizing tool wear. The results show that, within the range studied, the material removal rate depends mainly on tangential speed, followed by grain size and pressure. Tool wear is directly influenced by density of abrasive, followed by pressure, tangential speed, and grain size. According to the multi-objective optimization, if the two responses are given the same importance, it is recommended that high grain size, high density, high tangential speed, and low pressure be selected. Linear speed has less influence on both responses studied. If the material removal rate is considered to be more preponderant than tool wear, then the same values should be considered, except for high pressure. If tool wear is preponderant, then lower grain size of 128 (ISO 6106) should be selected, and lower tangential speed of approximately 166 min−1. The other variables, density and pressure, would not change significantly from the first situation. Full article
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15 pages, 5787 KiB  
Article
The Influence of the Material Type and the Placement in the Print Chamber on the Roughness of MJF-Printed 3D Objects
by Damian Dzienniak
Machines 2022, 10(1), 49; https://0-doi-org.brum.beds.ac.uk/10.3390/machines10010049 - 09 Jan 2022
Cited by 7 | Viewed by 1690
Abstract
This paper describes a surface-roughness study performed on samples manufactured additively using the Multi Jet Fusion (MJF) technology. The samples were divided into three groups based on the material used in the process: polypropylene (PP), thermoplastic polyurethane (TPU), and polyamide 11 (PA11). Subsequently, [...] Read more.
This paper describes a surface-roughness study performed on samples manufactured additively using the Multi Jet Fusion (MJF) technology. The samples were divided into three groups based on the material used in the process: polypropylene (PP), thermoplastic polyurethane (TPU), and polyamide 11 (PA11). Subsequently, they were tested by means of a roughness-measuring system, which made it possible to determine the typical surface roughness parameters (Ra, Rq, Rz). The tests were designed to examine whether the placement and orientation of 3D objects while printing, in connection with the material used, can significantly influence the surface quality of MJF-printed objects. The results show that the TPU samples have a surface roughness much higher than the PP and PA11 ones, which exhibit roughness levels very similar to each other. It can also be concluded that surfaces printed vertically (along the Z-axis) tend to be less smooth—similarly to the surfaces of objects made of TPU located in the central zones of the print chamber during printing. This information may be of value in cases where low surface roughness is preferred (e.g., manufacturing patient-specific orthoses), although this particular study does not focus on one specific application. Full article
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18 pages, 4607 KiB  
Article
Optimizing the Sharpening Process of Hybrid-Bonded Diamond Grinding Wheels by Means of a Process Model
by Eckart Uhlmann and Arunan Muthulingam
Machines 2022, 10(1), 8; https://0-doi-org.brum.beds.ac.uk/10.3390/machines10010008 - 22 Dec 2021
Cited by 1 | Viewed by 2487
Abstract
The grinding wheel topography influences the cutting performance and thus the economic efficiency of a grinding process. In contrary to conventional grinding wheels, super abrasive grinding wheels should undergo an additional sharpening process after the initial profiling process to obtain a suitable microstructure [...] Read more.
The grinding wheel topography influences the cutting performance and thus the economic efficiency of a grinding process. In contrary to conventional grinding wheels, super abrasive grinding wheels should undergo an additional sharpening process after the initial profiling process to obtain a suitable microstructure of the grinding wheel. Due to the lack of scientific knowledge, the sharpening process is mostly performed manually in industrial practice. A CNC-controlled sharpening process can not only improve the reproducibility of grinding processes but also decrease the secondary processing time and thereby increase the economic efficiency significantly. To optimize the sharpening process, experimental investigations were carried out to identify the significant sharpening parameters influencing the grinding wheel topography. The sharpening block width lSb, the grain size of the sharpening block dkSb and the area-related material removal in sharpening V’’Sb were identified as the most significant parameters. Additional experiments were performed to further quantify the influence of the significant sharpening parameters. Based on that, a process model was developed to predict the required sharpening parameters for certain target topographies. By using the process model, constant work results and improved process reliability can be obtained. Full article
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15 pages, 3046 KiB  
Article
Electropolishing Parametric Optimization of Surface Quality for the Fabrication of a Titanium Microchannel Using the Taguchi Method
by Muslim Mahardika, Martin Andre Setyawan, Tutik Sriani, Norihisa Miki and Gunawan Setia Prihandana
Machines 2021, 9(12), 325; https://0-doi-org.brum.beds.ac.uk/10.3390/machines9120325 - 29 Nov 2021
Cited by 8 | Viewed by 2607
Abstract
Titanium is widely used in biomedical components. As a promising advanced manufacturing process, electropolishing (EP) has advantages in polishing the machined surfaces of material that is hard and difficult to cut. This paper presents the fabrication of a titanium microchannel using the EP [...] Read more.
Titanium is widely used in biomedical components. As a promising advanced manufacturing process, electropolishing (EP) has advantages in polishing the machined surfaces of material that is hard and difficult to cut. This paper presents the fabrication of a titanium microchannel using the EP process. The Taguchi method was adopted to determine the optimal process parameters by which to obtain high surface quality using an L9 orthogonal array. The Pareto analysis of variance was utilized to analyze the three machining process parameters: applied voltage, concentration of ethanol in an electrolyte solution, and machining gap. In vitro experiments were conducted to investigate the fouling effect of blood on the microchannel. The result shows that an applied voltage of 20 V, an ethanol concentration of 20 vol.%, and a machining gap of 10 mm are the optimum machining parameters by which to enhance the surface quality of a titanium microchannel. Under the optimized machining parameters, the surface quality improved from 1.46 to 0.22 μm. Moreover, the adhesion of blood on the surface during the fouling experiment was significantly decreased, thus confirming the effectiveness of the proposed method. Full article
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15 pages, 5624 KiB  
Article
On-Machine Measurement and Error Compensation for 6061 Aluminum Alloy Hexagonal Punch Using a Turn-Milling Machine
by Cheng-Hsien Kuo and Po-Cheng Chen
Machines 2021, 9(9), 180; https://0-doi-org.brum.beds.ac.uk/10.3390/machines9090180 - 25 Aug 2021
Cited by 3 | Viewed by 2808
Abstract
For machining parts with complex shapes, consisting of computer numerical control (CNC) machine tools, different CNC machine tools will be used according to the machining method. If the workpiece is removed for off-machine measurement after machining, when the size is incorrect, it will [...] Read more.
For machining parts with complex shapes, consisting of computer numerical control (CNC) machine tools, different CNC machine tools will be used according to the machining method. If the workpiece is removed for off-machine measurement after machining, when the size is incorrect, it will need to be returned to the CNC machine tool for secondary machining. In this case, the workpiece surface quality and machining accuracy will be affected, which is very time-consuming. On-machine measurement and complex machine center is a key to solve this problem. In the recent researches that the touch probe was integrated on three or five axis machine for error compensation and shape construction based on on-machine measurement, but turning-milling machine was rare. In addition, the most types of parts were thin-walled parts or thin web parts. In this study, a contact measurement system is integrated into a CNC combined turning-milling machine for on-machine measuring. Macro-programming is used to design the machining path of A6061-T6 aluminum alloy hexagonal punch, and the action of probe measurement is added to the machining path. As the measured data exceed the tolerance range, the calculated data are fed back to the controller for machining improvement by compensation. The finished hexagonal punch is measured in a 3D coordinate measuring machine and the error is compared. The experimental results show that the contact probe needs to be corrected before machining, and the size of the corrected workpiece can reach the tolerance range of ±0.01 mm. The size error of rough machining is larger than that of fined machining, and the size error of rough machining will increase with the length of the workpiece. Full article
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18 pages, 1839 KiB  
Article
Study on the Importance of a Slicer Selection for the 3D Printing Process Parameters via the Investigation of G-Code Readings
by Jakub Bryła and Adam Martowicz
Machines 2021, 9(8), 163; https://0-doi-org.brum.beds.ac.uk/10.3390/machines9080163 - 11 Aug 2021
Cited by 5 | Viewed by 3524
Abstract
The work deals with the investigation of the variation of the selected 3D printing process properties that originate from the choice of a slicer. Specifically, the main aim of the present study was to assess the induced changes of the kinematic and geometric [...] Read more.
The work deals with the investigation of the variation of the selected 3D printing process properties that originate from the choice of a slicer. Specifically, the main aim of the present study was to assess the induced changes of the kinematic and geometric properties considered by the slicer for the printing process making use of the G-code readings. The paper provides adequate definitions and formulas required to characterize the slicer’s configuration. Next, the selected cases of the process parameters’ changes were studied, primarily taking into account varying layer height and infill. The authors performed a detailed analysis regarding the geometric implications at the mesoscale due to the slicer’s settings. Appropriate modifications of the slicer’s properties were also proposed and verified, making it possible to match the geometric and kinematic characteristics of the printed part. Full article
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12 pages, 2585 KiB  
Article
Evaluation of the Ability to Accurately Produce Angular Details by 3D Printing of Plastic Parts
by Andrei Marius Mihalache, Gheorghe Nagîț, Laurențiu Slătineanu, Adelina Hrițuc, Angelos Markopoulos and Oana Dodun
Machines 2021, 9(8), 150; https://0-doi-org.brum.beds.ac.uk/10.3390/machines9080150 - 29 Jul 2021
Cited by 2 | Viewed by 1613
Abstract
3D printing is a process that has become widely used in recent years, allowing the production of parts with relatively complicated shapes from metallic and non-metallic materials. In some cases, it is challenging to evaluate the ability of 3D printers to make fine [...] Read more.
3D printing is a process that has become widely used in recent years, allowing the production of parts with relatively complicated shapes from metallic and non-metallic materials. In some cases, it is challenging to evaluate the ability of 3D printers to make fine details of parts. For such an assessment, the printing of samples showing intersections of surfaces with low angle values was considered. An experimental plan was designed and materialized to highlight the influence of different factors, such as the thickness of the deposited material layer, the printing speed, the cooling and filling conditions of the 3D-printed part, and the thickness of the sample. Samples using areas in the form of isosceles triangles with constant height or bases with the same length, respectively, were used. The mathematical processing of the experimental results allowed the determination of empirical mathematical models of the power-function type. It allowed the detection of both the direction of actions and the intensity of the influence exerted by the input factors. It is concluded that the strongest influence on the printer’s ability to produce fine detail, from the point of view addressed in the paper, is exerted by the vertex angle, whose reduction leads to a decrease in printing accuracy. Full article
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22 pages, 5832 KiB  
Article
Simulation of the Circulating Motion of the Working Medium and Metal Removal during Multi-Energy Processing under the Action of Vibration and Centrifugal Forces
by János Kundrák, Andrey V. Mitsyk, Vladimir A. Fedorovich, Angelos P. Markopoulos and Anatoly I. Grabchenko
Machines 2021, 9(6), 118; https://0-doi-org.brum.beds.ac.uk/10.3390/machines9060118 - 17 Jun 2021
Cited by 9 | Viewed by 1644
Abstract
The rotational motion of the medium granules under the influence of an impeller installed in the bottom of a cylindrical reservoir is considered. The dependencies of the circulation velocity of the abrasive granules, as well as the dependence of the pressure in the [...] Read more.
The rotational motion of the medium granules under the influence of an impeller installed in the bottom of a cylindrical reservoir is considered. The dependencies of the circulation velocity of the abrasive granules, as well as the dependence of the pressure in the circulation flow of the granules on the radius of the vibrating machine cylindrical reservoir for different speeds of the impeller rotation are obtained. Furthermore, the velocities of the abrasive granules at various distances from the center of the cylindrical reservoir of the vibrating machine have been determined. The amplitudes of the tangential and radial components of the velocity of movement of pseudo-gas from abrasive granules are obtained. The total pressure on the surface of the processed part and the average velocity of the abrasive granules colliding with it are determined. The graphical dependencies of the integral metal removal on the amplitude and frequency of oscillations of the walls of the vibrating machine reservoir are given for various values of the angular velocities of the impeller rotation. Full article
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14 pages, 31448 KiB  
Article
Development of a New Finishing Process Combining a Fixed Abrasive Polishing with Magnetic Abrasive Finishing Process
by Yanhua Zou, Ryunosuke Satou, Ozora Yamazaki and Huijun Xie
Machines 2021, 9(4), 81; https://0-doi-org.brum.beds.ac.uk/10.3390/machines9040081 - 12 Apr 2021
Cited by 10 | Viewed by 3819
Abstract
High quality, highly efficient finishing processes are required for finishing difficult-to-machine materials. Magnetic abrasive finishing (MAF) process is a finishing method that can obtain a high accuracy surface using fine magnetic particles and abrasive particles, but has poor finishing efficiency. On the contrary, [...] Read more.
High quality, highly efficient finishing processes are required for finishing difficult-to-machine materials. Magnetic abrasive finishing (MAF) process is a finishing method that can obtain a high accuracy surface using fine magnetic particles and abrasive particles, but has poor finishing efficiency. On the contrary, fixed abrasive polishing (FAP) is a polishing process can obtain high material removal efficiency but often cannot provide a high-quality surface at the nano-scale. Therefore, this work proposes a new finishing process, which combines the magnetic abrasive finishing process and the fixed abrasive polishing process (MAF-FAP). To verify the proposed methodology, a finishing device was developed and finishing experiments on alumina ceramic plates were performed. Furthermore, the mechanism of the MAF-FAP process was investigated. In addition, the influence of process parameters on finishing characteristics is discussed. According to the experimental results, this process can achieve high-efficiency finishing of brittle hard materials (alumina ceramics) and can obtain nano-scale surfaces. The surface roughness of the alumina ceramic plate is improved from 202.11 nm Ra to 3.67 nm Ra within 30 min. Full article
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15 pages, 5120 KiB  
Article
Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy
by Nikolaos E. Karkalos, Panagiotis Karmiris-Obratański, Szymon Kurpiel, Krzysztof Zagórski and Angelos P. Markopoulos
Machines 2021, 9(4), 75; https://0-doi-org.brum.beds.ac.uk/10.3390/machines9040075 - 30 Mar 2021
Cited by 16 | Viewed by 3537
Abstract
Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance [...] Read more.
Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness. Full article
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16 pages, 4905 KiB  
Article
Adaptive Cutting Control for Roadheaders Based on Performance Optimization
by Qingyun Liu, Chao Lu, Tao Liu and Zhangbao Xu
Machines 2021, 9(3), 46; https://0-doi-org.brum.beds.ac.uk/10.3390/machines9030046 - 24 Feb 2021
Cited by 7 | Viewed by 2152
Abstract
Aiming at addressing the problems of high specific energy consumption for cutting and slow response to the change of hardness in the control of existing mining roadheaders, an adaptive variable speed cutting control method based on cutting performance optimization is proposed by analyzing [...] Read more.
Aiming at addressing the problems of high specific energy consumption for cutting and slow response to the change of hardness in the control of existing mining roadheaders, an adaptive variable speed cutting control method based on cutting performance optimization is proposed by analyzing the working principle of roadheaders. Firstly, cylinder pressure and motor current are invoked as the criteria to judge load changes. Particle swarm optimization is utilized to optimize the cutting parameters under different impedance. Then, the relation between cutting speed, motor current and cylinder pressure is established by using fuzzy neural network to train cutting parameters and identification parameters under different conditions. Finally, the vector control of motor and electro-hydraulic servo valve is used to control the cutting speed. The results show that the cutting unit can adapt to different load signals and always keep the roadheader in the optimal working state. The rotation speed regulation of the cutting head reaches the stable state after 0.05 s, with the overshoot of 1.42%. The swing speed regulation of the cutting head reaches the stable state after 1 s, with the overshoot of 5.3%. Conclusions provide a basis for improving the cutting efficiency and prolonging the working life of the roadheader. Full article
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