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Processes
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New Frontiers in Magnetic Polishing and Electrochemical Technology
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New Frontiers in Magnetic Polishing and Electrochemical Technology

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (30 April 2022) | Viewed by 20112

Special Issue Editors

Prof. Dr. A-Cheng Wang

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Chien Hsin University of Science and Technology, Taoyuan 320, Taiwan
Interests: magnetic abrasive finishing; abrasive flow machining; micro hole polishing; electrical discharge machining
Prof. Dr. Jung-Chou Hung

E-Mail Website
Guest Editor
Department of Mechanical Engineering, National Central University, Taoyuan 32001, Taiwan
Interests: electrochemical machining (ECM); electrical discharge machining (EDM); ultrasonic machining (USM); micromachining; array and batch processing; mold design and multiple physical simulation analysis for ECM; metal surface treatment, R&D of insulating materials; superalloy machining; non-conductor hard and brittle material processing; computer-integrated intelligent manufacturing

Special Issue Information

Dear Colleagues,

Some important components, such as turbine blades, hydraulic valves, inject nozzles, cooling channels, etc., provide beneficial properties—high mechanical strength, high temperature withstanding ability and good wear resistance—to apply in the precision industry; however, these components are not easy to make using traditional methods. Electrochemical technology and magnetic polishing are nontraditional means that can manufacture or finish these elements effectively by discharge erosion, electrolysis or magnetic abrasive polish. The above technologies can create self-sharpening, self-adaptability and self-controllability capabilities to remove material, deteriorated layers or micro cracks from workpieces and easily obtain precise and complex elements.

In recent years, many kinds of magnetic polishing and electrochemical technology have been developed via machining equipment, cutting tools and control methods in order to obtain high quality products, therefore, equipment functions, tool characteristics and control algorithms have likewise been widely studied in the past few decades. Moreover, machine learning in these technologies has also been investigated extensively due to great improvement in equipment performance and mass production of precision elements, especially micro elements and fine structures, which are easily made by the wisdom learning system.

This Special Issue welcomes novel processing research submissions, such as miniaturization, precision, composite, intelligent, multiple physical coupling, simulation analysis, difficult-to-machine appearance and inner hole feature processing, new material processing technology, etc. We hope that experts and scholars can contribute their research to this Special Issue. Thanks a lot.

Prof. Dr. A-Cheng Wang
Prof. Dr. Jung-Chou Hung
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. Processes 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

  • magnetic abrasive polishing
  • electrochemical technology
  • abrasive
  • machine learning
  • electrolysis
  • electrical discharge machining
  • laser machining
  • electromagnetic effects

Published Papers (7 papers)

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Research

12 pages, 4366 KiB  
Article
Study of the Polishing Characteristics by Abrasive Flow Machining with a Rotating Device
by Ken-Chuan Cheng, A-Cheng Wang, Kuan-Yu Chen and Chien-Yao Huang
Processes 2022, 10(7), 1362; https://0-doi-org.brum.beds.ac.uk/10.3390/pr10071362 - 13 Jul 2022
Cited by 6 | Viewed by 1876
Abstract
Since only uni-direction motion is produced by traditional abrasive flow machining (AFM), so the polishing effects of the inner hole is not easy to achieve uniform roughness of the whole surface after polishing. Therefore, in this study, a rotating device with a DC [...] Read more.
Since only uni-direction motion is produced by traditional abrasive flow machining (AFM), so the polishing effects of the inner hole is not easy to achieve uniform roughness of the whole surface after polishing. Therefore, in this study, a rotating device with a DC servo motor was set up in the AFM to increase the tangential forces on the machining surface, and therefore, improve the uniform surface roughness and polishing efficiency. The rotating device was designed by a group of transmission gear set and a DC servo motor to create a rotational finishing path for the abrasive medium. The rotational motion of an abrasive can create different tangential forces on the working surface, inducing a more complex polishing path than that of traditional AFM. In addition to rotational speed, a servo motor can also change rotation directions in one working process, causing an abrasive medium to create many irregular finishing paths in the AFM. The experimental results showed that the surface roughness of the workpiece was significantly decreased with an increase in the rotational speed. Additionally, the results also showed that the surface roughness (SR) of the inner hole decreased from 0.61 μm Ra to 0.082 μm Ra after 20 machining cycles, the surface roughness improvement rate reached 87% at 15 rpm rotational speed, by applying a 1.5:1 silicone gel/abrasive concentration ratio and #60 abrasive mesh in the experiments. This study created excellent polishing efficiency by using a servo rotational device with AFM to produce good surface quality. Full article
(This article belongs to the Special Issue New Frontiers in Magnetic Polishing and Electrochemical Technology)
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14 pages, 3628 KiB  
Article
Solutions of Feature and Hyperparameter Model Selection in the Intelligent Manufacturing
by Chung-Ying Wang, Chien-Yao Huang and Yen-Han Chiang
Processes 2022, 10(5), 862; https://0-doi-org.brum.beds.ac.uk/10.3390/pr10050862 - 27 Apr 2022
Cited by 3 | Viewed by 1639
Abstract
In the era of Industry 4.0, numerous AI technologies have been widely applied. However, implementation of the AI technology requires observation, analysis, and pre-processing of the obtained data, which takes up 60–90% of total time after data collection. Next, sensors and features are [...] Read more.
In the era of Industry 4.0, numerous AI technologies have been widely applied. However, implementation of the AI technology requires observation, analysis, and pre-processing of the obtained data, which takes up 60–90% of total time after data collection. Next, sensors and features are selected. Finally, the AI algorithms are used for clustering or classification. Despite the completion of data pre-processing, the subsequent feature selection and hyperparameter tuning in the AI model affect the sensitivity, accuracy, and robustness of the system. In this study, two novel approaches of sensor and feature selecting system, and hyperparameter tuning mechanisms are proposed. In the sensor and feature selecting system, the Shapley Additive ExPlanations model is used to calculate the contribution of individual features or sensors and to make the black-box AI model transparent, whereas, in the hyperparameter tuning mechanism, Hyperopt is used for tuning to improve model performance. Implementation of these two new systems is expected to reduce the problems in the processes of selection of the most sensitive features in the pre-processing stage, and tuning of hyperparameters, which are the most frequently occurring problems. Meanwhile, these methods are also applicable to the field of tool wear monitoring systems in intelligent manufacturing. Full article
(This article belongs to the Special Issue New Frontiers in Magnetic Polishing and Electrochemical Technology)
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17 pages, 8863 KiB  
Article
Deionized Water Electrochemical Machining Hybridized with Alumina Powder Polishing for Microcavity of M-333 Mold Steel
by Albert Wen-Jeng Hsue and Zih-Yuan Huang
Processes 2022, 10(1), 152; https://0-doi-org.brum.beds.ac.uk/10.3390/pr10010152 - 13 Jan 2022
Cited by 2 | Viewed by 1553
Abstract
An electrochemical machining (ECM) process for microcavity fabrication with deionized water (DI-water) and an ECM polishing hybrid with alumina powder of 1.0 μm grains on a single micro-EDM machine are proposed. The process adopts tungsten carbide as tool electrode and M-333 tool steel [...] Read more.
An electrochemical machining (ECM) process for microcavity fabrication with deionized water (DI-water) and an ECM polishing hybrid with alumina powder of 1.0 μm grains on a single micro-EDM machine are proposed. The process adopts tungsten carbide as tool electrode and M-333 tool steel as the mold material. It reveals that employing the 30 μm/min feed rate with 50 mA and 0.2 ms of pulse-width is suitable for DI-water electrochemical machining. The DI-water ECM process can achieve an excellent surface roughness at Ra 0.169 µm on a semispherical round cavity. Combining the ECM with hybrid polishing with the alumina powder can achieve a better profile for a much deeper cavity than pure electrolytic discharge machining. The hybrid ECM polishing can efficiently finish a micro square insert of 0.6 mm length at 64 μm depth. Such ECM milling can achieve an S-shaped microchannel of radius 1.0 mm and a slot of 1.0 × 0.5 mm2 with 110 μm depth, demonstrating its feasibility and the surface integrity with accurate profile and roughness of Ra 0.227 μm. This study provides a cost-effective scheme for micro mold fabrication with a conventional micro-EDM machine tool and an intuitive and convenient optional process. However, some micro-electrical discharges occurred due to the breakdown of insulation, which creates micro craters on the surface of the parts. Full article
(This article belongs to the Special Issue New Frontiers in Magnetic Polishing and Electrochemical Technology)
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14 pages, 5792 KiB  
Article
Study on Fe-Based Metallic Glass Micro Hole Machining by Using Micro-EDM Combined with Electrophoretic Deposition Polishing
by Hai-Ping Tsui and Shih-Yu Hsu
Processes 2022, 10(1), 96; https://0-doi-org.brum.beds.ac.uk/10.3390/pr10010096 - 04 Jan 2022
Cited by 8 | Viewed by 1595
Abstract
Fe-based metallic glass possesses high hardness and brittleness. It is a hard-to-cut metal material and difficult to machine by conventional methods. Although electrical discharge machining (EDM) has advantages in machining hard-to-cut metal materials, recast layer, pores, and micro cracks will form on the [...] Read more.
Fe-based metallic glass possesses high hardness and brittleness. It is a hard-to-cut metal material and difficult to machine by conventional methods. Although electrical discharge machining (EDM) has advantages in machining hard-to-cut metal materials, recast layer, pores, and micro cracks will form on the machined surface after machining. The study used a helical tool for the micro electrical discharge drilling (µ-EDD) process on Fe-based metallic glass. The influence of processing parameters, including the pulse on time, gap voltage, duty factor, and spindle rotational speed on the micro hole machining quality characteristics was investigated. The helical tool with SiC electrophoretic deposited (EPD) film was used to polish the inner surface of the electrical discharged micro hole. The findings show that the best micro hole accuracy, tool wear length, and inner surface were obtained at the spindle rotation speed of 1150 rpm, pulse on time of 5 μs, gap voltage of 30 V, and duty factor of 40%. The inner surface roughness can be reduced to 0.018 µm by using EPD tool. The inner surface was polished up to form a mirror surface. Full article
(This article belongs to the Special Issue New Frontiers in Magnetic Polishing and Electrochemical Technology)
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16 pages, 4372 KiB  
Article
Optimal Selection of Backside Roughing Parameters of High-Value Components Using Abrasive Jet Processing
by Feng-Che Tsai
Processes 2021, 9(9), 1661; https://0-doi-org.brum.beds.ac.uk/10.3390/pr9091661 - 14 Sep 2021
Viewed by 1787
Abstract
This paper mainly presents a set of new Sapphire Backside Roughing technology. Presently, the associated Sapphire Backside Roughing technology is still concentrated on chemical etching, as its yield rate and efficiency are often limited by lattice structures, and the derived chemical waste fluid [...] Read more.
This paper mainly presents a set of new Sapphire Backside Roughing technology. Presently, the associated Sapphire Backside Roughing technology is still concentrated on chemical etching, as its yield rate and efficiency are often limited by lattice structures, and the derived chemical waste fluid after etching is most likely to cause ecological contamination. In this research, refined abrasive jet processing technology is adopted, and in the meantime, the Taguchi experiment design method is taken for detailed experimental planning. Through processing parameter conditions and abrasive selection and development, proper surface roughing and processing uniformity are obtained so as to improve the various weak points of the abovementioned traditional etching effectively. It is discovered that abrasive blasting processing technology is, respectively, combined with wax-coated #1000 SiC particles and wax-coated #800 Zirconium particles to process the sapphire substrate with initial surface roughness 0.8–0.9 μmRa from the experiment. A 1.1–1.2 μmRa surface roughness effect can be achieved about two minutes later. The experimental results show that the actual degree of sapphire substrate surface roughing obtained in the AJM process depends on the gas pressure, impact angle, wax-coated abrasives, and additives. The new Sapphire Backside Roughing technology has high flexibility, which not only meets the requirements for sapphire surface roughing specification but can also effectively reduce the sapphire substrate roughing time and related cost. Full article
(This article belongs to the Special Issue New Frontiers in Magnetic Polishing and Electrochemical Technology)
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15 pages, 5372 KiB  
Article
An Investigation of Ultrasonic-Assisted Electrochemical Machining of Micro-Hole Array
by Zhe-Yong Shen and Hai-Ping Tsui
Processes 2021, 9(9), 1615; https://0-doi-org.brum.beds.ac.uk/10.3390/pr9091615 - 08 Sep 2021
Cited by 7 | Viewed by 2113
Abstract
This paper uses an ultrasonic vibration-integrated array electrode for 301 stainless steel micro-hole drilling. The influence of machining parameters such as ultrasonic vibration amplitude, working voltage, pulse-off time and electrode feed rate on different processing characteristics are discussed. The experimental results show that [...] Read more.
This paper uses an ultrasonic vibration-integrated array electrode for 301 stainless steel micro-hole drilling. The influence of machining parameters such as ultrasonic vibration amplitude, working voltage, pulse-off time and electrode feed rate on different processing characteristics are discussed. The experimental results show that the ultrasonic-assisted electrode array vibrating generates a periodic pressure difference for the electrolyte. The periodic pressure difference forms a pumping effect and a cavitation effect. The two effects can effectively renew the electrolyte in the machining gap and discharge the reaction product, gas and reaction heat from the gap. Machining speed can be increased by over 500% when the ultrasonic amplitude increases from 0.94 μm to 2.87 μm. Micro-hole drilling with the optimum experimental parameter combination of ultrasonic amplitude 2.87 μm, working voltage 11 V, pulse-off time 50 μs and electrode feed rate 5 μm/s can result in a minimum average diagonal length and a smaller amount of variation in diagonal length. It also improves the inlet and outlet taper angle of micro-holes. Full article
(This article belongs to the Special Issue New Frontiers in Magnetic Polishing and Electrochemical Technology)
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15 pages, 3508 KiB  
Article
Feedback Control of Melt Pool Area in Selective Laser Melting Additive Manufacturing Process
by Syed Zahid Hussain, Zareena Kausar, Zafar Ullah Koreshi, Shakil R. Sheikh, Hafiz Zia Ur Rehman, Haseeb Yaqoob, Muhammad Faizan Shah, Ahmad Abdullah and Farooq Sher
Processes 2021, 9(9), 1547; https://0-doi-org.brum.beds.ac.uk/10.3390/pr9091547 - 30 Aug 2021
Cited by 7 | Viewed by 3984
Abstract
Selective laser melting (SLM), a metal powder fusion additive manufacturing process, has the potential to manufacture complex components for aerospace and biomedical implants. Large-scale adaptation of these technologies is hampered due to the presence of defects such as porosity and part distortion. Nonuniform [...] Read more.
Selective laser melting (SLM), a metal powder fusion additive manufacturing process, has the potential to manufacture complex components for aerospace and biomedical implants. Large-scale adaptation of these technologies is hampered due to the presence of defects such as porosity and part distortion. Nonuniform melt pool size is a major cause of these defects. The melt pool size changes due to heat from the previous powder bed tracks. In this work, the effect of heat sourced from neighbouring tracks was modelled and feedback control was designed. The objective of control is to regulate the melt pool cross-sectional area rejecting the effect of heat from neighbouring tracks within a layer of the powder bed. The SLM process’s thermal model was developed using the energy balance of lumped melt pool volume. The disturbing heat from neighbouring tracks was modelled as the initial temperature of the melt pool. Combining the thermal model with disturbance model resulted in a nonlinear model describing melt pool evolution. The PID, a classical feedback control approach, was used to minimize the effect of intertrack disturbance on the melt pool area. The controller was tuned for the desired melt pool area in a known environment. Simulation results revealed that the proposed controller regulated the desired melt pool area during the scan of multiple tracks of a powder layer within 16 milliseconds and within a length of 0.04 mm reducing laser power by 10% approximately in five tracks. This reduced the chance of pore formation. Hence, it enhances the quality of components manufactured using the SLM process, reducing defects. Full article
(This article belongs to the Special Issue New Frontiers in Magnetic Polishing and Electrochemical Technology)
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