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E-raamat: Micro-Cutting: Fundamentals and Applications

(Newcastle University, UK), Edited by (Brunel University, UK)
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Micro-Cutting: Fundamentals and Applications comprehensively covers the state of the art research and engineering practice in micro/nano cutting: an area which is becoming increasingly important, especially in modern micro-manufacturing, ultraprecision manufacturing and high value manufacturing.

This book provides basic theory, design and analysis of micro-toolings and machines, modelling methods and techniques, and integrated approaches for micro-cutting. The fundamental characteristics, modelling, simulation and optimization of micro/nano cutting processes are emphasized with particular reference to the predictabilty, producibility, repeatability and productivity of manufacturing at micro and nano scales.

The fundamentals of micro/nano cutting are applied to a variety of machining processes including diamond turning, micromilling, micro/nano grinding/polishing, ultraprecision machining, and the design and implementation of micro/nano cutting process chains and micromachining systems.

Key features Contains contributions from leading global experts Covers the fundamental theory of micro-cutting Presents applications in a variety of machining processes Includes examples of how to implement and apply micro-cutting for precision and micro-manufacturing

Micro-Cutting: Fundamentals and Applications is an ideal reference for manufacturing engineers, production supervisors, tooling engineers, planning and application engineers, as well as machine tool designers. It is also a suitable textbook for postgraduate students in the areas of micro-manufacturing, micro-engineering and advanced manufacturing methods.
List of Contributors
xi
Series Preface xiii
Preface xv
PART ONE FUNDAMENTALS
1(2)
1 Overview of Micro Cutting
3(16)
Dehong Huo
Kai Cheng
1.1 Background and Scope
3(7)
1.1.1 Micro Manufacturing
3(2)
1.1.2 History and Development Process of Micro Cutting
5(2)
1.1.3 Definition and Scope of Micro Cutting
7(1)
1.1.4 Micro Cutting and Nanometric Cutting
8(2)
1.2 Materials in Micro Cutting
10(1)
1.3 Micro Cutting Processes
11(3)
1.3.1 Micro Turning
12(1)
1.3.2 Micro Milling
12(1)
1.3.3 Micro Drilling
13(1)
1.3.4 Micro Grinding
14(1)
1.4 Micro Cutting Framework
14(5)
References
16(3)
2 Micro Cutting Mechanics
19(26)
Dehong Huo
Kai Cheng
2.1 Introduction
19(1)
2.2 Characterization of Micro Cutting
20(5)
2.2.1 Micro Cutting and Ultra-Precision Machining
21(1)
2.2.2 Enabling Technologies for Micro Cutting
22(3)
2.3 Micro Cutting Mechanics
25(14)
2.3.1 Size Effects
26(1)
2.3.2 Chip Formation and Minimum Chip Thickness
27(2)
2.3.3 Specific Cutting Energy and Micro Cutting Force Modelling
29(4)
2.3.4 Surface Generation and Burr Formation
33(6)
2.4 Micro Machinability Issues and the Scientific Approaches
39(2)
2.4.1 Vibration Assisted Micro Cutting
40(1)
2.4.2 Laser Assisted Micro Cutting
40(1)
2.5 Summary
41(4)
References
42(3)
3 Micro Tooling Design and Manufacturing
45(18)
Paul T. Mativenga
Ampara Aramcharoen
Dehong Huo
3.1 Tool Size and Machining Scale
45(1)
3.2 Manufacturing Methods for Solid Shank Micro Tools
46(2)
3.3 Coatings and Coated Solid Shank Micro Tools
48(4)
3.3.1 Closed Field Unbalanced Magnetron Sputter Ion Plating (CFUBMSIP)
50(1)
3.3.2 Coating Layout
50(2)
3.4 Importance of Coated Micro Tools
52(1)
3.5 Diamond Micro Cutting Tools
53(2)
3.6 Micro Cutting Tool Wear
55(3)
3.7 Smart Cutting Tools
58(5)
References
59(4)
4 Ultraprecision and Micro Machine Tools for Micro Cutting
63(24)
Christian Brecher
Christian Wenzel
4.1 Introduction
63(1)
4.2 Components of High Precision Machine Tools
64(6)
4.2.1 Machine Base Materials
65(1)
4.2.2 Drive Systems
66(3)
4.2.3 Guidance Systems
69(1)
4.2.4 Control Systems and Amplifiers
70(1)
4.3 Diamond Turning Machines and Components
70(9)
4.3.1 Typical Machine Setup
71(2)
4.3.2 Market Comparison
73(5)
4.3.3 Fast Tool Servo Technology
78(1)
4.4 Precision Milling Machines
79(8)
References
85(2)
5 Engineering Materials for Micro Cutting
87(28)
Sathyan Subbiah
Shreyes N. Melkote
5.1 Introduction
87(1)
5.2 `Size' Effects
88(2)
5.3 Strain and Stress in Cutting
90(4)
5.4 Elastic and Plastic Behaviours at the Micro-scale
94(5)
5.5 Fracture
99(6)
5.6 Metals, Brittle Materials and Others
105(6)
5.6.1 Pure Materials
105(1)
5.6.2 Ductile Metals
106(1)
5.6.3 Brittle Materials - Glass, Silicon, Germanium, Tungsten Carbide
107(1)
5.6.4 Other Materials - Amorphous Alloys, Graphene and Embedded Polymers
108(3)
5.7 Summary
111(4)
References
112(3)
6 Modelling and Simulation of Micro Cutting
115(38)
Ying-Chun Liang
Qing-Shun Bai
Jia-Xuan Chen
6.1 FE modelling and Analysis
116(8)
6.1.1 Finite Element Model
116(1)
6.1.2 Simulation on Micro-burr Formation
117(1)
6.1.3 Influence of the Tool Edge Radius on Cutting Forces
118(2)
6.1.4 Stress Distribution on the Micro-cutter
120(1)
6.1.5 Micro-tool-tip Breakage
120(3)
6.1.6 Thermal Analysis on Micro Cutting
123(1)
6.2 Molecular Dynamics (MD) Modelling and Analysis
124(14)
6.2.1 MD Modelling Process and Simulation
124(3)
6.2.2 Modelling Analysis of Micro Cutting
127(1)
6.2.3 Scratching Simulation by Using MD
128(4)
6.2.4 Friction and Wear Simulation by Using MD
132(3)
6.2.5 Effect of the Crystal Plane of Single Crystal and Multicrystalline
135(2)
6.2.6 Improvement of the MD Simulation Capability
137(1)
6.3 Multiscale Modelling and Analysis
138(10)
6.3.1 Advance in Multiscale Simulation Methods
140(3)
6.3.2 Applications of Multiscale Simulation in Micro Cutting Processes
143(4)
6.3.3 Research Challenges and Future Trends
147(1)
6.4 Summary
148(5)
References
148(5)
PART TWO APPLICATIONS
153(2)
7 Diamond Turning and Micro Turning
155(30)
Dehong Huo
Kai Cheng
7.1 Introduction
155(1)
7.2 Ultra-precision Diamond Turning
155(11)
7.2.1 A Historical Perspective of Diamond Turning
156(2)
7.2.2 Material Perspectives
158(1)
7.2.3 Micro Structuring by Diamond Turning
159(7)
7.3 Micro Turning
166(16)
7.3.1 Micro Turning Tool Fabrication
166(5)
7.3.2 Micro Machines for Micro Turning
171(7)
7.3.3 Size Effect Arising from Micro Turning
178(4)
7.4 Challenges Arising from Micro Turning
182(3)
References
182(3)
8 Micro Milling: The State-of-the-art Approach Towards Applications
185(42)
Tao Wu
Kai Cheng
8.1 Introduction
185(1)
8.2 Fundamental Elements in Micro Milling
186(12)
8.2.1 Micro Milling Machines
187(2)
8.2.2 Cutting Tools
189(6)
8.2.3 Process Conditions
195(2)
8.2.4 Work Materials
197(1)
8.3 Micro Milling Mechanics
198(7)
8.3.1 Size Effect in Micro-Scale Cutting
198(2)
8.3.2 Minimum Chip Thickness
200(3)
8.3.3 Work Micro Structure Effect
203(2)
8.4 Modelling of the Micro Milling Process
205(7)
8.4.1 Finite Element Modelling
206(2)
8.4.2 Mechanistic Modelling
208(4)
8.5 Metrology and Instrumentation
212(5)
8.5.1 3D Surface Profilers
212(1)
8.5.2 Microscopes
212(2)
8.5.3 Process Monitoring Sensors and Systems
214(3)
8.6 Scientific and Technological Challenges
217(3)
8.6.1 Tool Run-out
217(1)
8.6.2 Tool Wear and Life
218(1)
8.6.3 Micro-Burr Formation
218(1)
8.6.4 Process Conditions Optimization
219(1)
8.7 Application Perspectives
220(1)
8.8 Concluding Remarks
220(7)
References
221(6)
9 Micro Drilling Applications
227(48)
M. J. Jackson
T. Novakov
K. Mosiman
9.1
Chapter Overview
227(1)
9.2 Investigation of Chatter in Mesoscale Drilling
227(30)
9.2.1 Torsional-axial Model
231(8)
9.2.2 Bending Model
239(3)
9.2.3 Combination of the Bending and Torsional-axial Models
242(9)
9.2.4 Chatter Suppression
251(5)
9.2.5 Research Challenges
256(1)
9.3 Investigation of Chatter in Micro Drilling
257(8)
9.4 Case Study: Micro Drilling Medical Polymer Materials and Composites
265(5)
9.4.1 Tooling Selection
266(1)
9.4.2 Cutting Mechanisms and Considerations
267(1)
9.4.3 Drilling
268(1)
9.4.4 Burr Elimination when Drilling Polymers
269(1)
9.5 Conclusions
270(5)
Acknowledgements
271(1)
References
272(3)
10 Micro Grinding Applications
275(40)
Han Huang
10.1 Introduction
275(3)
10.2 Principles and Methodologies
278(8)
10.2.1 Removal Mechanism in the Grinding of Brittle Materials
278(2)
10.2.2 Interaction Between a Work Material and Diamond Abrasives
280(5)
10.2.3 Grinding Approaches for Micro Grinding
285(1)
10.3 Implementation Perspectives
286(13)
10.3.1 Truing and Dressing
286(1)
10.3.2 Characterization of Wheel Topography and Cutting Edge Distribution
287(4)
10.3.3 Measurement of Grit Height Distribution
291(1)
10.3.4 Characterization of Abrasive Wear
292(1)
10.3.5 Compensation Grinding
292(5)
10.3.6 Pragmatic Aspects in Profile Grinding
297(1)
10.3.7 Parametric Effects in Profile Grinding
298(1)
10.4 Application Cases
299(16)
10.4.1 Micro Grinding of Aspherical Moulds
299(6)
10.4.2 Micro Grinding of Optical Fibre Connectors
305(6)
Acknowledgements
311(1)
References
311(4)
11 In-Process Micro/Nano Measurement for Micro Cutting
315(30)
Wei Gao
Kang-Won Lee
Young-Jin Noh
Yoshikazu Arai
Yuki Shimizu
11.1 Introduction
315(1)
11.2 The Hybrid Instrument for Micro Cutting and In-process Measurement
316(10)
11.3 In-process Measurement of Micro Cutting Force
326(5)
11.4 In-process Measurement of Micro Wear of Cutting Tool
331(6)
11.5 In-process Measurement of Micro Surface Form
337(5)
11.6 Summary
342(3)
References
343(2)
Index 345
Kai Cheng, Brunel University, UK

Professor Kai Cheng holds the chair professorship in Manufacturing Systems at Brunel University. His current research interests focus on micro manufacturing, design of precision machine tools, and global/sustainable manufacturing and systems. Professor Cheng has published over 160 papers in learned international journals and refereed conferences, authored/edited 5 books and contributed 6 book chapters.

Professor Cheng is a fellow of the IET and IMechE. He is the head of the Advanced Manufacturing and Enterprise Engineering (AMEE) Department at Brunel, which consists of 10 academics and over 30 research assistants and PhD students. Professor Cheng is the European editor of the International Journal of Advanced Manufacturing Technology and a member of the editorial board of International Journal of Machine Tools and Manufacture.
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