Machining of stainless steels and super alloys : traditional and nontraditional techniques / Helmi A. Youssef, Alexandria University, Egypt.

Format:

Book

Author/Creator:

Youssef, Helmi A., author.

Language:

English

Subjects (All):

Metal-cutting.

Stainless steel.

Chromium-cobalt-nickel-molybdenum alloys.

Physical Description:

1 online resource (306 p.)

Edition:

1st ed.

Place of Publication:

West Sussex, England : Wiley, 2016.

Language Note:

English

Summary:

Provides a comprehensive description for machining technologies of stainless steels and super alloys with consideration to current industrial applications. * Presents current and recent developments related to traditional and nontraditional machining techniques of stainless steels and super alloys * Arranges types of stainless steels and super alloys in qualitative and quantitative form, as related to their machining characteristics, providing the reader with information regarding optimum working condition for each material * Proposes a 10-level machinability chart to rank important grades of stainless steels * Arranges the machinability rating of the most commonly used super alloys in a descending order * Presents non-traditional machining processes along with some hybrid processes which have been applied successfully to stainless steels and super alloys

Contents:

Intro

Title Page

Copyright Page

Contents

Preface

About the Author

Acknowledgments

Nomenclature

Glossary

Chapter 1 Introduction

1.1 Stainless Steels and Super Alloys as Difficult-to-Cut Materials

1.1.1 Historical Background of Stainless Steels and Super Alloys

1.1.1.1 Stainless Steels

1.1.1.2 Super Alloys

1.1.2 Industrial Applications of Stainless Steels and Super Alloys

1.1.2.1 Stainless Steels

1.1.2.2 Super Alloys

1.2 Traditional and Nontraditional Machining Processes

1.2.1 Importance of Machining in Manufacturing Technology

1.2.2 Classification of Machining Processes

1.2.3 Variables of Machining Processes

1.2.3.1 Input (Independent) Variables

1.2.3.2 Output (Dependent) Variables

References

Chapter 2 Types and Classifications of Stainless Steels

2.1 Role of Alloying Elements in Stainless Steels

2.2 Types of Stainless Steels

2.2.1 Basic Alloys of Stainless Steels (Ferritic, Martensitic, Austenitic)

2.2.1.1 Ferritic Stainless Steels of AISI-Designations

2.2.1.2 Martensitic Stainless Steels also of AISI-Designation

2.2.1.3 Austenitic Stainless Steels of AISI-Designation

2.2.2 Derived Alloys of Stainless Steels (Duplex, PH-Alloys)

2.3 Concluding Comments and Comparative Characteristics

Chapter 3 Types and Classifications of Super Alloys

3.1 General Features and Classifications

3.2 Types of Super Alloys

3.2.1 Fe-Base Alloys

3.2.2 Ni-Base Alloys

3.2.3 Co-Base Alloys

Chapter 4 Traditional Machining - Machinability, Tooling, and Cutting Fluids

4.1 Machinability Concept in Metal Cutting

4.1.1 Definition and General Aspects

4.1.2 Quantifying and Criteria of Machinability

4.1.2.1 Tool Life Criterion

4.1.2.2 Cutting Forces and Power Consumption Criterion

4.1.2.3 Surface Finish Criterion.

4.1.3 Enhancing Machinability of Difficult-to-Cut Materials

4.1.3.1 Adoption of Free Machining Steels and Alloys

4.1.3.2 Thermally Assisted Machining (Hot Machining)

4.1.3.3 High Speed Machining

4.1.3.4 Ultrasonic-Assisted Machining

4.1.3.5 Advanced Cooling Techniques

4.1.3.6 Cryogenic Treatment of Tool Materials

4.2 Cutting Tool Materials

4.2.1 Characteristics of an Ideal Tool Material

4.2.2 Types of Cutting Tool Materials

4.2.2.1 High Speed Steel (HSS)

4.2.2.2 Cast Nonferrous Alloys (Stellite and UCON)

4.2.2.3 Cemented Carbides (Widia)

4.2.2.4 Cemented Titanium Carbides (TiC-Based Tools)

4.2.2.5 Cermets

4.2.2.6 Ceramics (Alumina-Based Tools)

4.2.2.7 SiAlON

4.2.2.8 Cubic Boron Nitride (CBN)

4.2.2.9 Diamond

4.2.3 Tool Materials for Machining of Stainless Steels and Super Alloys

4.2.3.1 Cutting Tool Materials for Stainless Steels

4.2.3.2 Tool Materials for Super Alloys

4.3 Cutting Fluids for Stainless Steels and Super Alloys

4.3.1 Functions, Characteristics, and General Considerations

4.3.2 Types of Cutting Fluids

4.3.2.1 Water-Base Liquids

4.3.2.2 Neat Oils

4.3.2.3 Liquid Gas or Cryogenic Coolants

4.3.2.4 Solid Lubricants

4.3.3 Application Methods

4.3.4 Cutting Fluids for Stainless Steels

4.3.4.1 Sulfo-chlorinated Cutting Oils

4.3.4.2 Emulsifiable Fluids

4.3.4.3 Selection of Cutting Fluid for Stainless Steels

4.3.5 Cutting Fluids for Super Alloys

4.3.5.1 Turning, Planing, Shaping, and Boring

4.3.5.2 Broaching

4.3.5.3 Drilling and Reaming

4.3.5.4 Tapping and Thread Cutting

4.3.5.5 Milling

4.3.5.6 Sawing

4.3.5.7 Grinding

Chapter 5 Traditional Machining of Stainless Steels

5.1 Machinability of Stainless Steels

5.1.1 Free-Machining Additives of Stainless Steels.

5.1.2 Machinability of Free- and Nonfree-Machining Stainless Steels

5.1.2.1 Ferritic and Martensitic Alloys

5.1.2.2 Austenitic Alloys

5.1.2.3 Duplex Alloys

5.1.2.4 PH-Alloys

5.1.3 Enhanced Machining Stainless Steels

5.1.4 Machinability Ratings of Stainless Steels

5.2 Traditional Machining Processes of Stainless Steels

5.2.1 Turning

5.2.1.1 Form Turning and Cutting Off

5.2.2 Drilling

5.2.2.1 Important Hints When Drilling Stainless Steels

5.2.3 Reaming

5.2.3.1 Tool Geometry of Reamers for Stainless Steels

5.2.3.2 Reaming Parameters

5.2.4 Milling

5.2.5 Broaching

5.2.6 Grinding

5.3 Surface Treatments of Stainless Steel after Machining

5.3.1 Chemical Cleaning (Pickling)

5.3.2 Passivating

Chapter 6 Traditional Machining of Super Alloys

6.1 Machinability Aspects of Super Alloys

6.2 Machinability Rating of Super Alloys

6.2.1 Machinability as Based on Tool Life and Nominal Cutting Speeds

6.2.2 Machinability as Based on Specific Cutting Energy

6.3 Traditional Machining Processes (TMPs) of Super Alloys

6.3.1 Challenges and Machining Guidelines for Super Alloys

6.3.2 Turning

6.3.3 Drilling

6.3.4 Reaming

6.3.5 Milling

6.3.6 Broaching

6.3.7 Grinding

6.3.7.1 Selection of Grinding Wheel Designation

Chapter 7 Nontraditional Machining Processes - an Overview

7.1 Nontraditional Machining Processes

7.2 Mechanical Nontraditional Processes

7.2.1 Jet Machining

7.2.1.1 Abrasive Jet Machining

7.2.1.2 Water Jet Machining

7.2.1.3 Abrasive Water Jet Machining

7.2.2 Abrasive Flow Machining

7.2.2.1 Parameters Affecting MRR of AFM

7.2.2.2 Advantages of AFM

7.2.3 Ultrasonic Machining

7.2.3.1 Transducer and Magnetostriction Effect

7.2.3.2 Acoustic Horns (Mechanical Amplifiers or Concentrators).

7.2.3.3 Process Capabilities

7.3 Electrochemical and Chemical Machining Processes

7.3.1 Electrochemical Machining

7.3.1.1 Process Capabilities

7.3.1.2 Pulsed Electrochemical Machining (PECM)

7.3.1.3 Shaped Tube Electrolytic Machining (STEM)

7.3.1.4 Electro-stream (ES) or Capillary Drilling

7.3.2 Electrochemical Grinding

7.3.3 Chemical Machining

7.3.3.1 Chemical Milling (CH-milling)

7.3.3.2 Photochemical Machining (Spray Etching)

7.4 Thermoelectric Processes

7.4.1 Electrical Discharge Machining

7.4.1.1 Types of Generators, Applicable for ED-Machines

7.4.1.2 Process Capabilities

7.4.2 Electron Beam Machining

7.4.3 Laser Beam Machining

7.4.4 Plasma Arc Cutting

7.5 Nontraditional Machining Processes - an Outlook

Chapter 8 Nontraditional Machining of Stainless Steels and Super Alloys

8.1 Mechanical Nontraditional Machining Processes of Stainless Steels and Super Alloys

8.1.1 Jet Machining

8.1.2 Ultrasonic Machining (USM) of Stainless Steels and Super Alloys

8.1.3 Abrasive Flow Machining of Stainless Steels and Super Alloys

8.2 Electrochemical and Chemical Machining Processes of Stainless Steels and Super Alloys

8.2.1 Electrochemical Machining

8.2.2 Shaped Tube Electrolytic Machining (STEM) of Stainless Steel and Super Alloys

8.2.3 Electro-stream (ES) Machining of Stainless Steel and Super Alloys

8.2.4 Electrochemical Grinding (ECG) of Stainless Steels and Super Alloys

8.2.5 Chemical Milling (CH-Milling)

8.2.5.1 MRR and Depth Tolerance

8.2.5.2 Surface Quality

8.2.6 Photochemical Machining (Spray Etching)

8.3 Thermoelectric Machining Processes

8.3.1 Electric Discharge Machining (EDM)

8.3.2 Electrical Discharge Milling of SSs and SAs

8.3.2.1 Fields of Applications of ED-Milling

8.3.2.2 Advantages and Limitations of ED-Milling.

8.3.3 Electron Beam Machining

8.3.4 Laser Beam Machining

8.3.5 Plasma Arc Cutting

8.4 Economical Analysis of ECM and Thermo-electrical Processes of Turbo-machinery Components

8.5 Nontraditional Micro-drilling of Deep Holes - a Comparison

8.6 Thermally-Assisted Machining of Stainless Steels and Super Alloys

8.6.1 Surface Integrity and Removal Rates for TAM of Stainless Steels and Super Alloys

8.6.2 Laser Assisted Turning (LAM) of Inconel-718

8.6.3 Plasma Assisted Turning (PAT) of Super Alloys and PH-Stainless Steel

Chapter 9 Current and Recent Developments Regarding Machining of Stainless Steels and Super Alloys

9.1 General Considerations

9.2 Recent Research Work Related to Traditional Machining of Stainless Steels

9.3 Recent Research Works Related to Traditional Machining of Super Alloys

9.4 Recent Research Work Related to Nontraditional Machining of Stainless Steels and Super Alloys

Appendix

Review Questions

Solved Questions

Unsolved Questions

Index

EULA.

Notes:

Description based upon print version of record.

Includes bibliographical references at the end of each chapters and index.

Description based on print version record.

ISBN:

9781118919514

1118919513

9781118919361

111891936X

OCLC:

910993870