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Advanced Machining Processes of Metallic Materials, 2nd Edition

Book Description

Advanced Machining Processes of Metallic Materials: Theory, Modelling and Applications, Second Edition, explores the metal cutting processes with regard to theory and industrial practice. Structured into three parts, the first section provides information on the fundamentals of machining, while the second and third parts include an overview of the effects of the theoretical and experimental considerations in high-level machining technology and a summary of production outputs related to part quality.

In particular, topics discussed include: modern tool materials, mechanical, thermal and tribological aspects of machining, computer simulation of various process phenomena, chip control, monitoring of the cutting state, progressive and hybrid machining operations, as well as practical ways for improving machinability and generation and modeling of surface integrity.

This new edition addresses the present state and future development of machining technologies, and includes expanded coverage on machining operations, such as turning, milling, drilling, and broaching, as well as a new chapter on sustainable machining processes. In addition, the book provides a comprehensive description of metal cutting theory and experimental and modeling techniques, along with basic machining processes and their effective use in a wide range of manufacturing applications.

The research covered here has contributed to a more generalized vision of machining technology, including not only traditional manufacturing tasks, but also potential (emerging) new applications, such as micro and nanotechnology.

  • Includes new case studies illuminate experimental methods and outputs from different sectors of the manufacturing industry
  • Presents metal cutting processes that would be applicable for various technical, engineering, and scientific levels
  • Includes an updated knowledge of standards, cutting tool materials and tools, new machining technologies, relevant machinability records, optimization techniques, and surface integrity

Table of Contents

  1. Cover image
  2. Title page
  3. Table of Contents
  4. Copyright
  5. Preface
  6. Nomenclature
    1. Latin Symbols
    2. Greek Symbols
    3. Abbreviations
  7. Chapter One. Introduction
    1. References
  8. Chapter Two. Metal Cutting Operations and Terminology
    1. Abstract
    2. 2.1 Classification of Machining Processes
    3. 2.2 Kinematics of Cutting Process and Cutting Parameters
    4. 2.3 Geometry of Cutting Tools
    5. References
  9. Chapter Three. Trends in Metal Cutting Theory and Practice
    1. Abstract
    2. 3.1 Evolution of Manufacturing Methods and Systems
    3. 3.2 Driven Factors in Modern Machining Technology
    4. 3.3 The Future of Manufacturing
    5. References
  10. Chapter Four. Cutting Tool Materials
    1. Abstract
    2. 4.1 Classification and Properties of Cutting Tool Materials
    3. 4.2 HSSs and Cast-Cobalt Alloys
    4. 4.3 Sintered Tungsten Carbides and Cermets
    5. 4.4 Ceramics
    6. 4.5 Superhard Materials
    7. 4.6 Cutting Tool Coatings
    8. 4.7 Rules for Applications of Cutting Tool Coatings
    9. References
  11. Chapter Five. Modelling and Simulation of Machining Processes and Operations
    1. Abstract
    2. 5.1 The Role of Modelling in Modern Production Systems
    3. 5.2 Classification of Models for Machining Processes
    4. 5.3 Modelling Techniques for Machining Processes
    5. 5.4 Data Needed for Modelling of Machining Processes
    6. References
  12. Chapter Six. Orthogonal and Oblique Cutting Mechanics
    1. Abstract
    2. 6.1 Geometrical and Kinematical Characterization
    3. 6.2 Forces in the Cutting Zone
    4. 6.3 Cutting Energy
    5. 6.4 Stresses on the Shear Plane
    6. 6.5 Plastic Deformation in the Cutting Zone
    7. References
  13. Chapter Seven. Chip Formation and Control
    1. Abstract
    2. 7.1 Chip Classification
    3. 7.2 Chip Formation Mechanisms
    4. 7.3 Modelling of Chip Formation
    5. 7.4 Chip Flow
    6. 7.5 Chip Breaking
    7. References
  14. Chapter Eight. Cutting Vibrations
    1. Abstract
    2. 8.1 Classification of Cutting Vibrations and Their Sources
    3. 8.2 Forced Vibrations in Milling Operations
    4. 8.3 Mechanisms of Self-Excitation in Metal Cutting
    5. 8.4 Stability of Chatter
    6. 8.5 Methods for Improving Machine Tool Stability
    7. References
  15. Chapter Nine. Heat in Metal Cutting
    1. Abstract
    2. 9.1 Heat Sources in Metal Cutting and Cutting Temperature
    3. 9.2 Heat Flow and Distribution in the Cutting Zone
    4. 9.3 Prediction and Modelling of Temperatures in the Cutting Zone
    5. 9.4 Measurements of Temperatures in the Cutting Zone
    6. References
  16. Chapter Ten. Cutting Fluids
    1. Abstract
    2. 10.1 Basic Categories of Cutting Fluids
    3. 10.2 Functions and Action of CFs
    4. 10.3 Application of CFs and Other Cooling/Lubrication Media
    5. 10.4 Maintenance and Disposal of CFs
    6. References
  17. Chapter Eleven. Tribology of Metal Cutting
    1. Abstract
    2. 11.1 Tribological Characterization of the Cutting Zone
    3. 11.2 Distribution of Stresses in the Tool-Chip Interface
    4. 11.3 Characterization of Friction at the Tool-Chip Interface
    5. 11.4 Measurements and Predictions of Contact Stresses and Friction
    6. References
  18. Chapter Twelve. Tool Wear and Damage
    1. Abstract
    2. 12.1 Types of Tool Wear
    3. 12.2 Physical Mechanisms of Tool Wear
    4. 12.3 Tool Life
    5. 12.4 Modelling of Tool Wear
    6. 12.5 Advanced Methods of Tool Wear Identification and Measurement
    7. References
  19. Chapter Thirteen. Machinability of Engineering Materials
    1. Abstract
    2. 13.1 Definition and Machinability Criteria
    3. 13.2 Machinability Rating
    4. 13.3 Machinability Data Systems
    5. 13.4 Survey of Machinability of Engineering Materials
    6. References
  20. Chapter Fourteen. Machining Economics and Optimization
    1. Abstract
    2. 14.1 Machining Economics
    3. 14.2 Optimization of Cutting Parameters
    4. 14.3 Advanced Methods of Optimization
    5. References
  21. Chapter Fifteen. Advanced Machining Processes
    1. Abstract
    2. Subchapter 15.1. High-Speed Machining
      1. Definition of Basic Features of HSM
      2. Physical Aspects of HSM
      3. HSC Technology and Appliances
      4. Basic Applications of HSC Technology
      5. Machining of Monolithic Parts
    3. Subchapter 15.2. Dry and Semi-Dry Machining
      1. The Way to Dry Machining
      2. Machine Tools and Equipment for Dry and Quasi-Dry Machining
      3. Dry Machining Operations
      4. Introduction of Near-Dry Machining
      5. MQL Media and Mixture Supplying Systems
      6. Machine Tools for Performing NDM Operations
    4. Subchapter 15.3. Hard Part Machining
      1. Definition of Basic Feature of Hard Part Machining
      2. Physical Aspects of Hard Machining
      3. Applications of HM Technology
      4. Surface Finish Produced by HPM
    5. Subchapter 15.4. High-Performance and High-Efficiency Machining
      1. Basic Aspects of High-Performance and High-Efficiency Machining
      2. Machine Tools and Tooling
      3. Simplifying and Improving Machining Operations
    6. Subchapter 15.5. Multitasking and One-Pass Machining
      1. Background of Multitasking Machining
      2. Multitasking Machine Tools and Tooling
      3. One-Pass Machining
    7. Subchapter 15.6. Ultrasonically and Thermally Assisted Hybrid Machining Processes
      1. Ultrasonically Assisted Machining and Ultrasonic Vibration Cutting
      2. Laser-Assisted Machining
      3. Plasma-Assisted Machining
  22. Chapter Sixteen. Micro-Machining
    1. Abstract
    2. 16.1 Definition and Miniaturization
    3. 16.2 A Survey of Micro-Machining Processes
    4. 16.3 Micro-Machines and Equipment
    5. 16.4 Examples of Micro-Machining Products
    6. 16.5 Tooling and Fixturing for Micro-Machining
    7. 16.6 Metrology for Micro-Machining Processes and Products
    8. References
  23. Chapter Seventeen. Nanomanufacturing/Nanotechnology
    1. Abstract
    2. 17.1 Definition and State of the Art of Nanomanufacturing
    3. 17.2 Ultra-Precision Machines and Nanoscale Machining Operations
    4. 17.3 Examples of Nanoproducts
    5. 17.4 Nanometrology
    6. References
  24. Chapter Eighteen. Sensor-Assisted Machining
    1. Abstract
    2. 18.1 Sensors and System Architecture
    3. 18.2 Practical Examples of Monitoring Systems for Metal Cutting Applications
    4. 18.3 Touch-Trigger Probing and Laser Measuring Systems
    5. 18.4 Sensor-Guided and Intelligent/Smart Tools
    6. References
  25. Chapter Nineteen. Virtual/Digital and Internet-Based Machining
    1. Abstract
    2. 19.1 Overview of the Manufacturing Evolution
    3. 19.2 Digital/Virtual Manufacturing
    4. 19.3 Internet-Based Manufacturing
    5. References
  26. Chapter Twenty. Surface Integrity
    1. Abstract
    2. 20.1 Superficial Layer and Surface Integrity
    3. 20.2 Surface Roughness Evaluation
    4. 20.3 Surface Roughness Measurements
    5. 20.4 Properties of Subsurface Layer
    6. References
  27. Index