Advanced machining processes of metallic materials : theory, modelling, and applications / Wit Grzesik, Professor of Mechanical Engineering, Faculty of Mechanical Engineering, Opole University of Technology, Poland.

Format:

Book

Author/Creator:

Grzesik, Wit, author.

Language:

English

Subjects (All):

Metal-cutting.

Metal-cutting tools.

Metal-cutting--Data processing.

Physical Description:

1 online resource (610 pages) : illustrations

Edition:

Second edition.

Place of Publication:

Amsterdam : Elsevier, [2017]

System Details:

text file

Summary:

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

Contents:

Front Cover

Advanced Machining Processes of Metallic Materials

Copyright Page

Contents

Preface

Nomenclature

Latin Symbols

Greek Symbols

Abbreviations

1. Introduction

References

2. Metal Cutting Operations and Terminology

2.1 Classification of Machining Processes

2.2 Kinematics of Cutting Process and Cutting Parameters

2.3 Geometry of Cutting Tools

3. Trends in Metal Cutting Theory and Practice

3.1 Evolution of Manufacturing Methods and Systems

3.2 Driven Factors in Modern Machining Technology

3.3 The Future of Manufacturing

4. Cutting Tool Materials

4.1 Classification and Properties of Cutting Tool Materials

4.2 HSSs and Cast-Cobalt Alloys

4.3 Sintered Tungsten Carbides and Cermets

4.4 Ceramics

4.5 Superhard Materials

4.6 Cutting Tool Coatings

4.7 Rules for Applications of Cutting Tool Coatings

5. Modelling and Simulation of Machining Processes and Operations

5.1 The Role of Modelling in Modern Production Systems

5.2 Classification of Models for Machining Processes

5.3 Modelling Techniques for Machining Processes

5.4 Data Needed for Modelling of Machining Processes

6. Orthogonal and Oblique Cutting Mechanics

6.1 Geometrical and Kinematical Characterization

6.2 Forces in the Cutting Zone

6.3 Cutting Energy

6.4 Stresses on the Shear Plane

6.5 Plastic Deformation in the Cutting Zone

7. Chip Formation and Control

7.1 Chip Classification

7.2 Chip Formation Mechanisms

7.3 Modelling of Chip Formation

7.4 Chip Flow

7.5 Chip Breaking

8. Cutting Vibrations

8.1 Classification of Cutting Vibrations and Their Sources

8.2 Forced Vibrations in Milling Operations

8.3 Mechanisms of Self-Excitation in Metal Cutting

8.4 Stability of Chatter.

8.5 Methods for Improving Machine Tool Stability

9. Heat in Metal Cutting

9.1 Heat Sources in Metal Cutting and Cutting Temperature

9.2 Heat Flow and Distribution in the Cutting Zone

9.3 Prediction and Modelling of Temperatures in the Cutting Zone

9.3.1 Calculation of Temperature Rise Due to Plastic Deformation in the PDZ

9.3.2 Calculation of Average and Maximum Interface Temperatures

9.3.3 FEM and FDA Prediction of Cutting Temperature

9.4 Measurements of Temperatures in the Cutting Zone

10. Cutting Fluids

10.1 Basic Categories of Cutting Fluids

10.2 Functions and Action of CFs

10.3 Application of CFs and Other Cooling/Lubrication Media

10.4 Maintenance and Disposal of CFs

11. Tribology of Metal Cutting

11.1 Tribological Characterization of the Cutting Zone

11.2 Distribution of Stresses in the Tool-Chip Interface

11.3 Characterization of Friction at the Tool-Chip Interface

11.4 Measurements and Predictions of Contact Stresses and Friction

12. Tool Wear and Damage

12.1 Types of Tool Wear

12.2 Physical Mechanisms of Tool Wear

12.3 Tool Life

12.4 Modelling of Tool Wear

12.5 Advanced Methods of Tool Wear Identification and Measurement

13. Machinability of Engineering Materials

13.1 Definition and Machinability Criteria

13.2 Machinability Rating

13.3 Machinability Data Systems

13.4 Survey of Machinability of Engineering Materials

13.4.1 Carbon/Unalloyed Steels

13.4.2 Alloyed Steels

13.4.3 Stainless Steels

13.4.4 Cast Irons

13.4.5 Titanium and Its Alloys

13.4.6 Nickel-Based Alloys

13.4.7 Lightweight Materials

13.4.8 Composite Materials

13.4.9 Refractory Metals

14. Machining Economics and Optimization

14.1 Machining Economics.

14.2 Optimization of Cutting Parameters

14.2.1 Procedure Based on Tool-Life Equation

14.2.2 Procedure Based on Energy Efficiency Criterion

14.3 Advanced Methods of Optimization

15. Advanced Machining Processes

15.1 High-Speed Machining

15.1.1 Definition of Basic Features of HSM

15.1.2 Physical Aspects of HSM

15.1.3 HSC Technology and Appliances

15.1.4 Basic Applications of HSC Technology

15.1.5 Machining of Monolithic Parts

15.2 Dry and Semi-Dry Machining

15.2.1 The Way to Dry Machining

15.2.2 Machine Tools and Equipment for Dry and Quasi-Dry Machining

15.2.3 Dry Machining Operations

15.2.4 Introduction of Near-Dry Machining

15.2.5 MQL Media and Mixture Supplying Systems

15.2.6 Machine Tools for Performing NDM Operations

15.3 Hard Part Machining

15.3.1 Definition of Basic Feature of Hard Part Machining

15.3.2 Physical Aspects of Hard Machining

15.3.3 Applications of HM Technology

15.3.4 Surface Finish Produced by HPM

15.4 High-Performance and High-Efficiency Machining

15.4.1 Basic Aspects of High-Performance and High-Efficiency Machining

15.4.2 Machine Tools and Tooling

15.4.3 Simplifying and Improving Machining Operations

15.5 Multitasking and One-Pass Machining

15.5.1 Background of Multitasking Machining

15.5.2 Multitasking Machine Tools and Tooling

15.5.3 One-Pass Machining

15.6 Ultrasonically and Thermally Assisted Hybrid Machining Processes

15.6.1 Ultrasonically Assisted Machining and Ultrasonic Vibration Cutting

15.6.2 Laser-Assisted Machining

15.6.3 Plasma-Assisted Machining

16. Micro-Machining

16.1 Definition and Miniaturization

16.2 A Survey of Micro-Machining Processes

16.3 Micro-Machines and Equipment.

16.4 Examples of Micro-Machining Products

16.5 Tooling and Fixturing for Micro-Machining

16.6 Metrology for Micro-Machining Processes and Products

17. Nanomanufacturing/Nanotechnology

17.1 Definition and State of the Art of Nanomanufacturing

17.2 Ultra-Precision Machines and Nanoscale Machining Operations

17.3 Examples of Nanoproducts

17.4 Nanometrology

18. Sensor-Assisted Machining

18.1 Sensors and System Architecture

18.2 Practical Examples of Monitoring Systems for Metal Cutting Applications

18.3 Touch-Trigger Probing and Laser Measuring Systems

18.4 Sensor-Guided and Intelligent/Smart Tools

19. Virtual/Digital and Internet-Based Machining

19.1 Overview of the Manufacturing Evolution

19.2 Digital/Virtual Manufacturing

19.3 Internet-Based Manufacturing

20. Surface Integrity

20.1 Superficial Layer and Surface Integrity

20.2 Surface Roughness Evaluation

20.3 Surface Roughness Measurements

20.4 Properties of Subsurface Layer

Index

Back Cover.

Notes:

Includes bibliographical references and index.

Description based on online resource; title from PDF title page (ebrary, viewed November 22, 2016).

ISBN:

0-444-63720-6