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E-raamat: Advanced Machining Processes of Metallic Materials: Theory, Modelling, and Applications

(Professor of Mechanical Engineering, Technical University of Opole, Poland)
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  • Ilmumisaeg: 15-Nov-2016
  • Kirjastus: Elsevier Science Ltd
  • Keel: eng
  • ISBN-13: 9780444637208
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Advanced Machining Processes of Metallic Materials: Theory, Modelling, and ApplicationsSuurem pilt
  • Formaat: EPUB+DRM
  • Ilmumisaeg: 15-Nov-2016
  • Kirjastus: Elsevier Science Ltd
  • Keel: eng
  • ISBN-13: 9780444637208
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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 maching 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, and surface integrity

Muu info

Fully updated text that is ideal for anyone in machine-related businesses, including machining technologists, machine tool manufacturers, designers, builders, and more
Preface ix
Nomenclature xiii
1 Introduction
1(6)
References
5(2)
2 Metal Cutting Operations and Terminology
7(14)
2.1 Classification of Machining Processes
7(6)
2.2 Kinematics of Cutting Process and Cutting Parameters
13(4)
2.3 Geometry of Cutting Tools
17(4)
References
20(1)
3 Trends in Metal Cutting Theory and Practice
21(14)
3.1 Evolution of Manufacturing Methods and Systems
21(3)
3.2 Driven Factors in Modern Machining Technology
24(8)
3.3 The Future of Manufacturing
32(3)
References
33(2)
4 Cutting Tool Materials
35(30)
4.1 Classification and Properties of Cutting Tool Materials
35(3)
4.2 HSSs and Cast-Cobalt Alloys
38(1)
4.3 Sintered Tungsten Carbides and Cermets
39(5)
4.4 Ceramics
44(2)
4.5 Superhard Materials
46(4)
4.6 Cutting Tool Coatings
50(10)
4.7 Rules for Applications of Cutting Tool Coatings
60(5)
References
62(3)
5 Modelling and Simulation of Machining Processes and Operations
65(28)
5.1 The Role of Modelling in Modern Production Systems
65(3)
5.2 Classification of Models for Machining Processes
68(4)
5.3 Modelling Techniques for Machining Processes
72(9)
5.4 Data Needed for Modelling of Machining Processes
81(12)
References
90(3)
6 Orthogonal and Oblique Cutting Mechanics
93(20)
6.1 Geometrical and Kinematical Characterization
93(2)
6.2 Forces in the Cutting Zone
95(7)
6.3 Cutting Energy
102(2)
6.4 Stresses on the Shear Plane
104(2)
6.5 Plastic Deformation in the Cutting Zone
106(7)
References
111(2)
7 Chip Formation and Control
113(34)
7.1 Chip Classification
113(4)
7.2 Chip Formation Mechanisms
117(9)
7.3 Modelling of Chip Formation
126(8)
7.4 Chip Flow
134(4)
7.5 Chip Breaking
138(9)
References
145(2)
8 Cutting Vibrations
147(16)
8.1 Classification of Cutting Vibrations and Their Sources
147(2)
8.2 Forced Vibrations in Milling Operations
149(2)
8.3 Mechanisms of Self-Excitation in Metal Cutting
151(3)
8.4 Stability of Chatter
154(4)
8.5 Methods for Improving Machine Tool Stability
158(5)
References
161(2)
9 Heat in Metal Cutting
163(20)
9.1 Heat Sources in Metal Cutting and Cutting Temperature
163(2)
9.2 Heat Flow and Distribution in the Cutting Zone
165(4)
9.3 Prediction and Modelling of Temperatures in the Cutting Zone
169(6)
9.3.1 Calculation of Temperature Rise Due to Plastic Deformation in the PDZ
169(1)
9.3.2 Calculation of Average and Maximum Interface Temperatures
170(1)
9.3.3 FEM and FDA Prediction of Cutting Temperature
171(4)
9.4 Measurements of Temperatures in the Cutting Zone
175(8)
References
181(2)
10 Cutting Fluids
183(14)
10.1 Basic Categories of Cutting Fluids
183(3)
10.2 Functions and Action of CFs
186(2)
10.3 Application of CFs and Other Cooling/Lubrication Media
188(5)
10.4 Maintenance and Disposal of CFs
193(4)
References
195(2)
11 Tribology of Metal Cutting
197(18)
11.1 Tribological Characterization of the Cutting Zone
197(4)
11.2 Distribution of Stresses in the Tool-Chip Interface
201(5)
11.3 Characterization of Friction at the Tool-Chip Interface
206(4)
11.4 Measurements and Predictions of Contact Stresses and Friction
210(5)
References
213(2)
12 Tool Wear and Damage
215(26)
12.1 Types of Tool Wear
215(5)
12.2 Physical Mechanisms of Tool Wear
220(3)
12.3 Tool Life
223(6)
12.4 Modelling of Tool Wear
229(4)
12.5 Advanced Methods of Tool Wear Identification and Measurement
233(8)
References
239(2)
13 Machinability of Engineering Materials
241(24)
13.1 Definition and Machinability Criteria
241(4)
13.2 Machinability Rating
245(3)
13.3 Machinability Data Systems
248(2)
13.4 Survey of Machinability of Engineering Materials
250(15)
13.4.1 Carbon/Unalloyed Steels
250(1)
13.4.2 Alloyed Steels
251(1)
13.4.3 Stainless Steels
252(1)
13.4.4 Cast Irons
253(2)
13.4.5 Titanium and Its Alloys
255(2)
13.4.6 Nickel-Based Alloys
257(3)
13.4.7 Lightweight Materials
260(1)
13.4.8 Composite Materials
261(2)
13.4.9 Refractory Metals
263(1)
References
263(2)
14 Machining Economics and Optimization
265(20)
14.1 Machining Economics
265(4)
14.2 Optimization of Cutting Parameters
269(6)
14.2.1 Procedure Based on Tool-Life Equation
269(3)
14.2.2 Procedure Based on Energy Efficiency Criterion
272(3)
14.3 Advanced Methods of Optimization
275(10)
References
283(2)
15 Advanced Machining Processes
285(114)
15.1 High-Speed Machining
285(17)
15.2 Dry and Semi-Dry Machining
302(21)
15.3 Hard Part Machining
323(20)
15.4 High-Performance and High-Efficiency Machining
343(25)
15.5 Multitasking and One-Pass Machining
368(14)
15.6 Ultrasonically and Thermally Assisted Hybrid Machining Processes
382(17)
16 Micro-Machining
399(38)
16.1 Definition and Miniaturization
399(4)
16.2 A Survey of Micro-Machining Processes
403(4)
16.3 Micro-Machines and Equipment
407(11)
16.4 Examples of Micro-Machining Products
418(6)
16.5 Tooling and Fixturing for Micro-Machining
424(6)
16.6 Metrology for Micro-Machining Processes and Products
430(7)
References
435(2)
17 Nanomanufacturing/Nanotechnology
437(30)
17.1 Definition and State of the Art of Nanomanufacturing
437(5)
17.2 Ultra-Precision Machines and Nanoscale Machining Operations
442(11)
17.3 Examples of Nanoproducts
453(9)
17.4 Nanometrology
462(5)
References
464(3)
18 Sensor-Assisted Machining
467(38)
18.1 Sensors and System Architecture
467(11)
18.2 Practical Examples of Monitoring Systems for Metal Cutting Applications
478(11)
18.3 Touch-Trigger Probing and Laser Measuring Systems
489(10)
18.4 Sensor-Guided and Intelligent/Smart Tools
499(6)
References
503(2)
19 Virtual/Digital and Internet-Based Machining
505(28)
19.1 Overview of the Manufacturing Evolution
505(5)
19.2 Digital/Virtual Manufacturing
510(11)
19.3 Internet-Based Manufacturing
521(12)
References
530(3)
20 Surface Integrity
533(30)
20.1 Superficial Layer and Surface Integrity
533(6)
20.2 Surface Roughness Evaluation
539(11)
20.3 Surface Roughness Measurements
550(4)
20.4 Properties of Subsurface Layer
554(9)
References
560(3)
Index 563
Wit Grzesik, MSc, PhD, DSc Professor of Mechanical Engineering, obtained an M.Sc. in mechanical engineering from the Technical University of Wroclaw, Poland, in 1973, a Ph.D. in manufacturing engineering from this university in 1981, and a D.Sc. (habilitation) in mechanical engineering from Warsaw University of Technology in 1988. From 1973 to 1975 he worked in industry as a design engineer. In 1975 he joined the Technical University of Opole, Poland. He has been a faculty member in the Department of Manufacturing Engineering as Assistant Professor from 1982 to 1988, Associate Professor from 1988 to 1991 and Professor to 1999. At present he is a Full Professor and Chairman of the Department of Manufacturing Engineering and Production Automation at the Technical University of Opole. He has published more than 140 papers in journals and conference proceedings, two research monographs on metal cutting mechanics and machinability of austenitic stainless steels, and three books on machining of metallic materials, advanced coatings for engineering applications and programming of CNC machine tools. His research interests include the theory and modeling of metal removal processes, monitoring of manufacturing processes, surface integrity, quality engineering and CAD/CAM and modern manufacturing systems. Currently, he is a Member of two Sections of the Polish Academy of Science, and a Member of ESAFORM and a Senior Member of the NAMRI/SME (U.S.)
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