Machining

Fundamentals and Recent Advances

By: J. Paulo Davim (Editor)

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Hardcover | 24 September 2008

At a Glance

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376 Pages

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23.39 x 15.6 x 2.24

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Machining is one of the most important manufacturing processes. Parts manufactured by other processes often require further operations before the product is ready for application. "Machining: Fundamentals and Recent Advances" is divided into two parts. Part I explains the fundamentals of machining, with special emphasis on three important aspects: mechanics of machining, tools, and work-piece integrity. Part II is dedicated to recent advances in machining, including: machining of hard materials, machining of metal matrix composites, drilling polymeric matrix composites, ecological machining (minimal quantity of lubrication), high-speed machining (sculptured surfaces), grinding technology and new grinding wheels, micro- and nano-machining, non-traditional machining processes, and intelligent machining (computational methods and optimization). Advanced students, researchers and professionals interested or involved in modern manufacturing engineering will find the book a useful reference.

Industry Reviews

Supplementary processes for material removal... such as electric discharge machining, electrochemical machining, ultrasonic machining, laser beam machining, and nanomachining have been in service for several decades. However, despite the extensive use of these processes, several questions remain unanswered. This book represents a fresh attempt to provide the long-overdue answers to some of these research questions. Its 12 chapters present the contributions of 24 of the best-qualified minds of eight countries. The first three chapters cover the basics of machining, with the remainder of the book focusing on newer techniques. Anyone with a research interest in the field of material removal will find this a valuable resource and a worthy addition to their professional and personal libraries... Recommended.

Choice (July 2009) (Reviewer: K. Srinagesh, University of Massachusetts Dartmouth)

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Non-Fiction Engineering & Technology Technology in General Engineering in General Mechanical Engineering & Materials Materials Science Mechanical Engineering Industrial Chemistry & Manufacturing Technologies Metals Technology & Metallurgy Production & Industrial Engineering

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Paperback

Published: 13th October 2010

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Metal Cutting Mechanics, Finite Element Modelling	p. 1
Advanced Metal Cutting Mechanics	p. 1
Objective of Metal Cutting Mechanics	p. 1
State of the Art	p. 1
Advanced Methodology	p. 4
Combined Influence of the Minor Cutting Edge	p. 7
Influence of the Cutting Speed, Depth of Cut and Cutting Feed on Power Partition	p. 9
Concluding Remarks	p. 11
Finite Element Analysis (FEA)	p. 13
Numerical Formulations	p. 14
Modelling Chip Separation from the Workpiece and Chip Segmentation	p. 15
Mesh Design	p. 16
Work Material Modelling	p. 18
Modelling of Contact Conditions	p. 19
Numerical Integration	p. 19
Errors	p. 20
Example	p. 20
Advanced Numerical Modelling	p. 21
Model Validation	p. 22
References	p. 25
Tools (Geometry and Material) and Tool Wear	p. 29
Essentials of Tool Geometry	p. 29
Importance of the Cutting Tool Geometry	p. 29
Basic Terms and Definitions	p. 31
System of Considerations	p. 32
Basic Tool Geometry Components	p. 33
Influence of the Tool Angles	p. 35
Tool Materials	p. 37
Carbides	p. 39
Ceramics	p. 43
Cubic Boron Nitride (CBN)	p. 44
Polycrystalline Diamond (PCD) and Solid Film Diamond (SFD)	p. 45
Tool Wear	p. 48
Tool Wear Types	p. 48
Tool Wear Evolution	p. 50
Mechanisms of Tool Wear	p. 52
Tool Life	p. 52
Taylor's Tool Life Formula	p. 53
Expanded Taylor's Tool Life Formula	p. 55
Recent Trends in Tool Life Evaluation	p. 55
References	p. 57
Workpiece Surface Integrity	p. 59
What Does Surface Integrity Mean?	p. 59
Link Between Surface Integrity and its Manufacturing Procedure	p. 62
Impact of the Surface Integrity on the Dimensional Accuracy	p. 64
Impact of the Surface Integrity on Fatigue Resistance	p. 67
Material and Mechanical Aspects of Surface Integrity	p. 68
Mechanisms Leading to Material and Mechanical Modifications in Machining	p. 68
Modelling of Residual Stresses	p. 74
Experimental Approach	p. 80
References	p. 91
Machining of Hard Materials	p. 97
Basic Features of HM	p. 97
Definition of Hard Machining	p. 97
Comparison with Grinding Operations	p. 98
Technological Processes Including Hard Machining	p. 100
Equipment and Tooling	p. 101
Machine Tools	p. 101
Cutting Tools and Materials	p. 102
Complete Machining Using Hybrid Processes	p. 104
Characterization of Hard Machining Processes	p. 105
Cutting Forces	p. 105
Chip Formation	p. 105
Cutting Temperature	p. 108
Wear of Ceramic and PCBN Tools	p. 110
Modelling of Hard Cutting Processes	p. 110
Surface Integrity in Hard Machining Processes	p. 113
Surface Roughness	p. 113
Residual Stresses	p. 114
Micro/Nanohardness Distribution and White-Layer Effect	p. 115
Modification of Surface Finish in Hybrid Processes	p. 117
Cutting Errors and Dimensional Accuracy	p. 118
Applications of Hard Machining Processes	p. 119
Hard Turning	p. 119
Hard and High-Speed Milling of Dies and Moulds	p. 120
Hard Reaming	p. 121
Hard Broaching	p. 122
Hard Skive Hobbing	p. 122
Optimization of Hard Machining Processes	p. 123
References	p. 124
Machining of Particulate-Reinforced Metal Matrix Composites	p. 127
Introduction	p. 127
Effect of Reinforcement Particles on Surface Integrity and Chip Formation	p. 129
Strength of MMC During Machining	p. 130
Chip Shape	p. 131
Surface Integrity	p. 135
Shear and Friction Angles	p. 142
Relation Between Shear and Friction Angles	p. 144
Forces	p. 145
Modelling	p. 147
Forces	p. 147
Tool-Particle Interaction	p. 157
Tool Wear	p. 159
Performance of Cutting Tools	p. 159
Modelling of Tool Wear	p. 161
Acknowledgements	p. 162
References	p. 162
Drilling Polymeric Matrix Composites	p. 167
Introduction	p. 167
What Are Polymeric Matrix Composites?	p. 167
The Importance of Drilling	p. 171
Drilling Technology of Polymeric Matrix Composites	p. 173
Conventional Drilling Process	p. 173
Unconventional Drilling Processes	p. 178
Modelling of Conventional Drilling	p. 179
The Need for Modelling	p. 179
Cutting Force Modelling	p. 180
Damage Generated During Drilling and Residual Mechanical Properties	p. 183
Structural Damage	p. 183
Residual Mechanical Properties	p. 186
Damage Suppression Methods	p. 188
Introduction	p. 188
Process Parameters Selection	p. 188
Drilling Conditions	p. 189
Special Tools	p. 190
References	p. 191
Ecological Machining: Near-dry Machining	p. 195
Introduction	p. 195
Amount and Cost	p. 196
Health and Environmental Aspects	p. 197
Principal Directions in the Reduction of MWF Economical, Ecological and Health Impacts	p. 198
Nearly Dry Machining (NDM)	p. 201
How NDM Operates	p. 201
Classification of NDM	p. 202
Why NDM Works	p. 212
Consideration of the NDM System Components	p. 217
References	p. 221
Sculptured Surface Machining	p. 225
Introduction	p. 225
The Manufacturing Process	p. 227
Technologies Involved	p. 228
Five-axis Milling	p. 229
The CAM, Centre of Complex Surfaces Production	p. 231
Workpiece Precision	p. 233
Cutting Forces	p. 235
Workpiece Roughness	p. 237
Tool Path Selection Using Cutting Force Prediction	p. 239
Three-axis Case	p. 240
Five-axis Case	p. 241
Examples	p. 242
Three-axis Mould	p. 242
Five-axis Mould	p. 243
Three-axis Deep Mould	p. 245
Present and Future	p. 246
Acknowledgements	p. 246
References	p. 247
Grinding Technology and New Grinding Wheels	p. 249
Introduction	p. 249
High-efficiency Grinding Using Conventional Abrasive Wheels	p. 250
Introduction	p. 250
Grinding Wheel Selection	p. 251
Grinding Machine Requirements for High-efficiency Dressing	p. 253
Diamond Dressing Wheels	p. 253
Application of Diamond Dressing Wheels	p. 256
Modifications to the Grinding Process	p. 257
Selection of Grinding Process Parameters	p. 257
Selection of Cooling Lubricant Type and Application	p. 258
High-efficiency Grinding Using CBN Grinding Wheels	p. 258
Introduction	p. 258
Grinding Wheel Selection	p. 259
Grinding Machine Requirements for High-efficiency CBN Grinding	p. 264
Dressing High-efficiency CBN Grinding Wheels	p. 265
Selection of Dressing Parameters for High-efficiency CBN Grinding	p. 266
Selection of Cooling Lubrication for High-efficiency CBN Grinding Wheels	p. 266
Internet Resources	p. 267
References	p. 269
Micro and Nanomachining	p. 271
Introduction	p. 271
Machining Effects at the Microscale	p. 272
Shear Angle Prediction	p. 275
Plastic Behaviour at Large Strains	p. 278
Langford and Cohen's Model	p. 278
Walker and Shaw's Model	p. 279
Usui's Model	p. 280
Saw-tooth Chip Formation in Hard Turning	p. 281
Fluid-like Flow in Chip Formation	p. 281
Size Effects in Micromachining	p. 282
Nanomachining	p. 282
Nanometric Machining	p. 283
Theoretical Basis of Nanomachining	p. 284
Comparison of Nanometric Machining and Conventional Machining	p. 294
Acknowledgements	p. 295
References	p. 295
Advanced (Non-traditional) Machining Processes	p. 299
Introduction	p. 299
Mechanical Advanced Machining Processes (MAMP)	p. 301
Ultrasonic Machining (USM)	p. 301
Abrasive Water Jet Cutting (AWJC)	p. 304
Thermoelectric Advanced Machining Processes	p. 307
Electric Discharge Machining (EDM) and Wire EDM	p. 307
Laser Beam Machining (LBM)	p. 312
Electrochemical Advanced Machining Processes	p. 313
Electrochemical Machining (ECM)	p. 313
ECM Machine	p. 315
Fine Finishing Processes	p. 317
Abrasive Flow Machining (AFM)	p. 317
Magnetic Abrasive Finishing (MAF)	p. 320
Magnetic Float Polishing (MFP)	p. 323
Micromachining	p. 324
Finished Surface Characteristics	p. 325
References	p. 325
Intelligent Machining: Computational Methods and Optimization	p. 329
Intelligent Machining	p. 329
Neural Network Modelling	p. 332
Fuzzy Set Theory	p. 339
Neuro-fuzzy Modelling	p. 344
A Note on FEM Modelling	p. 347
Machining Optimization	p. 348
Objective Functions and Constraints	p. 348
Optimization Techniques	p. 350
Future Challenges	p. 355
References	p. 356
Index	p. 359
Table of Contents provided by Ingram. All Rights Reserved.

Machining

Fundamentals and Recent Advances

At a Glance

Hardcover

Industry Reviews

Shipping

How to return your order

Defective items

You Can Find This Book In

Other Editions and Formats

Paperback

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