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Manufacturing Technology: Materials, Innovations and Applications

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

Deadline for manuscript submissions: 10 May 2024 | Viewed by 7603

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Special Issue Editors

Prof. Dr. Dariusz Lipiński

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Guest Editor

Faculty of Mechanical Engineering, Koszalin University of Technology, 75-620 Koszalin, Poland
Interests: manufacturing technology; simulation, modelling and optimisation of machining processes; machining quality; applications of artificial intelligence

Prof. Dr. Wojciech Kacalak

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Guest Editor

Faculty of Mechanical Engineering, Koszalin University of Technology, 75-620 Koszalin, Poland
Interests: mechanical engineering; machine technology; mechatronics; applications of artificial intelligence
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Mirosław Pajor

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Faculty of Mechanical Engineering and Mechatronics, West Pomeranian University of Technology, 70-310 Szczecin, Poland
Interests: modelling and research of machining processes; dynamics of machine tools and robots; designing of machine diagnostic systems; intelligent man-machine interfaces and mechatronics
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Mariusz Deja

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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
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Prof. Dr. Błażej Bałasz

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Faculty of Mechanical Engineering, Koszalin University of Technology, 75-620 Koszalin, Poland
Interests: metal additive manufacturing; SLM; binder jetting; modelling and simulation of metal AM

Special Issue Information

Dear Colleagues,

The development of manufacturing technology is the basis for the expected changes in the industry as a response to global economic, social and environmental challenges. The challenges of the new industrial era make it necessary to take an interdisciplinary look at the problems and challenges related to manufacturing technologies. Recognizing these challenges and formulating solutions requires the consideration of knowledge in the field of materials engineering, chemistry, physics, mechanical engineering, electronics, mechatronics, IT, transport, logistics, finance and economics.

This Special Issue is a platform for the exchange of knowledge and the experience of scientists related to innovations in the field of manufacturing technology, the development of subtractive, additive and hybrid machining processes, circular economy and sustainable production. The scope of the Special Issue includes, among others, the following research topics:

Supervision and monitoring of subtractive, additive and hybrid machining processes;
Simulation, prediction and optimisation of manufacturing processes;
Development of machining tools and machining devices;
Application of digitisation, virtualisation methods as well as artificial intelligence methods in product design and manufacturing processes;
Innovations in automation and human–machine interfaces;
Eco-design, eco-manufacturing and sustainable production;
Recycling, waste management and circular economy in manufacturing processes.

Prof. Dr. Dariusz Lipiński
Prof. Dr. Wojciech Kacalak
Prof. Dr. Mirosław Pajor
Prof. Dr. Mariusz Deja
Prof. Dr. Błażej Bałasz
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

innovations in manufacturing
additive manufacturing
intelligent manufacturing
dynamics of machine tools and robots
design for additive manufacturing
developing new tools and machines
monitoring and control in manufacturing processes
simulation and modelling in manufacturing processes
man-machine interface
applications of artificial intelligence

Published Papers (10 papers)

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Research

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18 pages, 15835 KiB

Open AccessArticle

Exploring the Potential Application of an Innovative Post-Weld Finishing Method in Butt-Welded Joints of Stainless Steels and Aluminum Alloys

by Olga Łastowska, Robert Starosta, Monika Jabłońska and Andrzej Kubit

Materials 2024, 17(8), 1780; https://0-doi-org.brum.beds.ac.uk/10.3390/ma17081780 - 12 Apr 2024

Viewed by 277

Abstract

The prerequisite of the weld bead finishing is intricately linked to the quality of the welded joint. It constitutes the final, yet pivotal, stage in its formation, significantly influencing the reliability of structural components and machines. This article delineates an innovative post-weld surface finishing method, distinguished by the movement of a specialized cutting tool along a butt weld. This method stands out due to its singular approach to machining allowance, wherein the weld bead height is considered and eradicated in a single pass of the cutting tool. Test samples were made of AISI 304L, AISI 316L stainless steels and EN AW-5058 H321, EN AW-7075 T651 aluminum alloys butt-welded with TIG methods. Following the welding process, the weld bead was finished in accordance with the innovative method to flush the bead and the base metal’s surface. For the quality control of welded joints before and after the weld finishing, two non-destructive testing methods were chosen: Penetrant Testing (PT) and Radiographic Testing (RT). This article provides results from the examination of 2D profile parameters and 3D stereometric characteristics of surface roughness using the optical method. Additionally, metallographic results are presented to assess changes in the microstructure, the microhardness, and the degree of hardening within the surface layer induced by the application of the innovative post-weld finishing method. Full article

(This article belongs to the Special Issue Manufacturing Technology: Materials, Innovations and Applications)

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13 pages, 3320 KiB

Open AccessArticle

The Optimal Design of the Press Roller to Improve the Winding Molding Quality of Heat Insulation

by Weichao Zhang, Zengxuan Hou, Hongli Li and Kaiyin Chen

Materials 2024, 17(8), 1769; https://0-doi-org.brum.beds.ac.uk/10.3390/ma17081769 - 12 Apr 2024

Viewed by 359

Abstract

In the heat insulation winding molding process of solid rocket motors, the pressure applied by the press roller directly affects the quality of the winding molding. Insufficient pressure can result in poor bonding quality and may cause defects. This paper aims to provide an optimal design of the press roller to improve the winding molding quality of the heat insulation. The effect of the cylindrical press roller on the pressure distribution was analyzed using the elastic foundation model and a finite element (FE) model, which was assessed by Hertz theory. Subsequently, the press roller was optimized to an elliptical concave design. The effect of the radius of the elliptical concave press roller on the pressure distribution was analyzed. A comparison of the effect of the elliptical concave press roller and the cylindrical press roller on the pressure distribution was conducted using the FE model. The results show pressure uniformity is significantly improved when the elliptical concave press roller is employed on the mandrel with the smallest radius. Additionally, the elliptical concave press roller increases the pressure at the edge of the tape, which reduces the risk of lifted edges and, thereby, improves the winding molding quality of the heat insulation. Full article

(This article belongs to the Special Issue Manufacturing Technology: Materials, Innovations and Applications)

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17 pages, 9794 KiB

Open AccessArticle

Selected Aspects of Precision Grinding Processes Optimization

by Wojciech Kacalak, Dariusz Lipiński and Filip Szafraniec

Materials 2024, 17(3), 607; https://0-doi-org.brum.beds.ac.uk/10.3390/ma17030607 - 26 Jan 2024

Viewed by 468

Abstract

The paper describes selected aspects of the optimization of grinding processes, taking into account the characteristic probabilistic features of this process. Characteristic features of the grinding process that influence the significant dispersion of the quantities used in the optimization process to define goals and limitations are indicated. Attention was paid to the reasons for uncertainty in the use of research results, imperfections in information extraction procedures and the limited amount of data in the use of simulation and regression models in optimization procedures. The issue of determining the durability of abrasive tools in grinding process optimization procedures was analyzed. Methodologies for defining tool life are specified, taking into account the dispersion of the values of controlled process parameters. The effects of interference were taken into account in the relationships describing grinding efficiency and costs. The benefits of optimization taking into account the probabilistic nature of the process were determined. Full article

(This article belongs to the Special Issue Manufacturing Technology: Materials, Innovations and Applications)

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17 pages, 15526 KiB

Open AccessArticle

Analysis of the Process and Results of High-Pressure Abrasive Water Jet Multilayer Cutting of Electrical Steel

by Monika Szada-Borzyszkowska, Wojciech Kacalak, Łukasz Bohdal and Wiesław Szada-Borzyszkowski

Materials 2024, 17(1), 94; https://0-doi-org.brum.beds.ac.uk/10.3390/ma17010094 - 24 Dec 2023

Cited by 2 | Viewed by 871

Abstract

Electrical steels are magnetically soft materials and are widely used in the electrical industry for the construction of power transformer cores, distribution transformers, current transformers, and voltage transformers. An important parameter of electrical components, which determines the efficiency of devices, is energy loss during remagnetization. Energy losses are caused by eddy currents, hysteresis, and magnetic delay associated with the low quality of the cut edge after the cutting of steels, and material deformations and excessive stress concentration in the surrounding cutting zones. Common techniques for cutting electrical materials in industrial lines include mechanical cutting and laser cutting. Work has shown that mechanical cutting of electrical steel single layers results in the occurrence of large deformation zones, and in cutting processes with a high-pressure abrasive water jet (AWJ), significant uplifts of material and burrs at the bottom edges of sheets occur. The problem of increasing the cutting quality was solved through selecting the stream parameters for bundle cutting of electrical steels. It has been shown that in the process of cutting electrical sheet bundles, the height of burrs on the cut surface and the zone of plastic deformation are reduced. The work also presents comparison and analysis of characteristic features of the cut edge of electrical sheets obtained through high-pressure abrasive water jet and mechanical cutting processes. The influence of the type and processing parameters on the characteristic features of the material hysteresis loop was determined. Full article

(This article belongs to the Special Issue Manufacturing Technology: Materials, Innovations and Applications)

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19 pages, 17117 KiB

Open AccessArticle

The Effect of the Surface Topography of High-Speed Steel Cutting Blades Made Using Various Methods on Their Technological and Functional Properties

by Maciej Jan Kupczyk, Jędrzej Komolka and Jerzy Józwik

Materials 2023, 16(19), 6442; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16196442 - 27 Sep 2023

Viewed by 531

Abstract

Indication of the proper scope of application of high-speed steels (HSS) produced by conventional methods and powder metallurgy for cutting tool blades requires a thorough assessment of their properties in various cutting conditions. According to common knowledge, the properties of tools made of both types of steel are largely determined by the arrangement of carbide phases. It turns out, however, that the surface morphology of the cutting blades is at least as important for their operational properties. This was already indicated by the preliminary research of the authors of the article, in which it was found that the surface topography significantly affects their durability depending on the applied value of the cutting speed in dry machining conditions and in the presence of a cooling lubricant. As it turned out, contrary to the literature data, blades made of sintered HSS do not have better service properties in all cutting conditions than blades made by conventional methods (e.g., in forging and hot rolling processes). Hence, it was necessary to determine the justified range of use of both types of steel for cutting blades. Cutting blades with a similar chemical composition from conventional high-speed steel and those produced in the powder metallurgy process were tested. Wear curves were determined on the basis of the tests. On this basis, for the assumed value of the blunting index, the tool life of the cutting edges was determined during the cutting of selected structural steel, commonly used for high-strength machine parts. Tests of the cutting ability of the blades were carried out without and with the use of a cooling--lubricating liquid. In order to correctly interpret the obtained results of the wear and durability tests of the cutting edges, verification tests were carried out. A detailed analysis of the research material made it possible to determine the recommended range of applicability of conventional and sintered HSS for the tested case. Full article

(This article belongs to the Special Issue Manufacturing Technology: Materials, Innovations and Applications)

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16 pages, 5743 KiB

Open AccessArticle

Quenched Residual Stress Reduction in Pentagon-Curved Aluminum Alloy Forgings Using the Bulging Process

by Chuanwei Luo, Chen Li, Xinquan Zhang, Yunxin Wu and Tao Zhang

Materials 2023, 16(17), 5910; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16175910 - 29 Aug 2023

Viewed by 571

Abstract

Quenched residual stress in pentagon-curved forgings (PCGs) often leads to severe deformation during subsequent machining operations. This study aims to mitigate the quenched residual stress in PCGs through the implementation of the bulging method. The edge distance ratio (e/D), a geometric characteristic of PCGs, is defined and considered in the established thermo-mechanical model, which incorporates the effects of quenched residual stress. Increasing e/D resulted in amplified maximum internal stresses and surface stresses. To address this issue, a bulging finite element (FE) model was developed to effectively alleviate the quenched residual stress. The stress reduction in surface stress and internal stress was qualified using average stress reduction (

R_{a}

) and peak stress reduction (

R_{p}

), respectively. Notably, stress reduction exhibited an inverse relationship with e/D, indicating that decreasing e/D yields greater stress reduction. Furthermore, an overall stress reduction assessment was conducted for different bulging ratios, revealing that the stress reduction increased as the bulging ratio increased. A comprehensive comparison of different bulging ratios highlighted 2% as the most optimal bulging ratio for stress reduction in PCGs. X-ray diffraction measurement and the contour method were employed to determine surface stress and internal stress, respectively. The experimental results were in agreement with the simulation outcomes, validating the high accuracy of the FE model. Full article

(This article belongs to the Special Issue Manufacturing Technology: Materials, Innovations and Applications)

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16 pages, 5597 KiB

Open AccessArticle

Oblique Vibratory Surface Grinding—Experimental Study

by Grzegorz Bechcinski, Norbert Kepczak, Witold Pawlowski, Wojciech Stachurski and Paulina Byczkowska

Materials 2023, 16(17), 5819; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16175819 - 25 Aug 2023

Viewed by 746

Abstract

The article reports the results of experimental study of vibratory surface grinding in the range of low excitation frequencies and variable directions of excited vibrations in the plane of the table, and investigates the effect of these directions on the roughness and waviness of the ground surface. The tests were conducted on a production surface grinder with a vibrating table on which the samples were mounted. The table made it possible to change the direction for the introduction of vibrations to the workpiece (longitudinally, transversely, and obliquely to the longitudinal feed of the table) and the parameters of the introduced vibrations, frequency and amplitude. In the course of the study, selected parameters of surface roughness and waviness of samples ground conventionally and with vibrations introduced on the workpiece were compared. The results show an improvement in the roughness and waviness parameters of the vibration-ground surfaces compared to surfaces ground without vibration (conventionally). The profile of the ground surface was subjected to Fourier analysis and the harmonic components of the surface shape of the ground samples were determined to characterize the effect of the introduced vibrations on the surface roughness. It was determined that the direction of vibration introduction, which is most favorable in terms of the parameters of the geometric structure of the ground surface, is the direction perpendicular to the longitudinal feed of the grinding table. In other directions of vibration introduction, the simultaneous effect of improving both parameters of the geometric structure of the ground surface profile was not obtained. Full article

(This article belongs to the Special Issue Manufacturing Technology: Materials, Innovations and Applications)

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17 pages, 9886 KiB

Open AccessArticle

Investigation of the Impact of High-Speed Machining in the Milling Process of Titanium Alloy on Tool Wear, Surface Layer Properties, and Fatigue Life of the Machined Object

by Jakub Matuszak, Kazimierz Zaleski and Andrzej Zyśko

Materials 2023, 16(15), 5361; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16155361 - 30 Jul 2023

Cited by 3 | Viewed by 932

Abstract

This article presents the results of experimental research on the effect of high-speed machining (HSM) in the milling process on the tool wear, surface layer properties, and fatigue life of objects made of Ti-6Al-4V titanium alloy. Titanium alloys are widely used in many industries due to their high strength-to-density ratio, corrosion resistance, and resistance to dynamic loads. The experiment was conducted on a vertical three-axis machining centre, Avia VMC800HS. The influence of increased cutting speeds on the average values and amplitudes of the total cutting force components and the surface roughness of the machined workpiece was determined. Variable cutting speeds v_c = 70; 130; 190; 250; 310 m/min were applied. The impact of HSM on machinability indicators, such as the microhardness of the surface layer, the distribution of residual stresses, and the fatigue life of the samples after milling, was analysed. The thickness of the hardened layer varied from 20 to 28 micrometres. The maximum compressive residual stress Ϭ_m = 190 MPa was achieved at the speed of v_c = 190 m/min. A significant influence of increased cutting speeds on tool wear was demonstrated. The longest tool life (t = 70 min) was obtained for low cutting speeds (conventional) v_c = 70 m/min. Full article

(This article belongs to the Special Issue Manufacturing Technology: Materials, Innovations and Applications)

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15 pages, 11461 KiB

Open AccessArticle

Influence of Innovative Post-Weld Finishing Method on Bead Surface Quality

by Olha Dvirna, Agata Wieczorska, Norbert Abramczyk and Anna Lesnau

Materials 2023, 16(14), 5100; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16145100 - 19 Jul 2023

Viewed by 687

Abstract

The article describes an innovative post-weld surface finishing method, which is characterized by moving a specialized cutting tool along a butt weld. The aforementioned method is unique for the machining allowance, which is treated as the weld bead height and is removed in one step with one pass of the cutting tool. The tool is equipped on one side with linearly arranged tooth-shaped cutting elements, with the adjacent teeth height changing and increasing according to the direction of the feed. The non-standard geometry of the cutting tool enables the finishing of a heterogeneous post-weld surface with increased hardness. The results of studying the 2D profile parameters and the 3D stereometric characteristics of the surface roughness using the optical method are presented in the article. Test samples were made of S235JR steel and butt welded with the MMA, MIG, and TIG methods. Subsequently, the welding bead was ground and finished in accordance with the innovative method to flush the bead and the base metal’s surface. Additionally, residual stress analyses were performed using the X-ray diffraction method in the surface layers of the test samples. Based on the conducted research, the influence of the innovative finishing method on the surface quality is described. Full article

(This article belongs to the Special Issue Manufacturing Technology: Materials, Innovations and Applications)

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Review

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24 pages, 6814 KiB

Open AccessReview

Review of Cutting Temperature Measurement Methods

by Piotr Cichosz, Paweł Karolczak and Kamil Waszczuk

Materials 2023, 16(19), 6365; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16196365 - 22 Sep 2023

Cited by 1 | Viewed by 1374

Abstract

During the cutting process, large quantities of emitted heat are concentrated on a small surface area of the interface between the workpiece and the cutting edge. The resultant very high temperature significantly affects the tool life. Knowledge of maximum temperatures to be expected on the cutting edges is important, as it allows the cutting conditions to be adjusted in such a manner that the critical value of thermal resistance is not exceeded for the cutting material. In effect, the maximum effectiveness of the working process is maintained. This article offers a systematic presentation of methods used in cutting temperature measurements. It discusses their advantages and disadvantages, as well as the usefulness of the individual methods in different types of machining processes. It also points to the possibility of methodological errors which significantly reduce measurement accuracy. The above issues are believed to justify a discussion of different cutting temperature measurement methods. The conclusions here presented may be of particular importance to researchers interested in the field, especially in high-efficiency machining, new cutting materials and cutting-edge protective coatings, as well as various methods for cutting fluid applications. They may allow a more informed selection of measurement methods most suitable for particular situations. Full article

(This article belongs to the Special Issue Manufacturing Technology: Materials, Innovations and Applications)

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