Machining

This book is the third in the Woodhead Publishing Reviews: Mechanical Engineering Series, and includes high quality articles (full research articles, review articles and case studies) with a special emphasis on research and development in machining and machine-tools. Machining and machine tools is an important subject with application in several industries. Parts manufactured by other processes often require further operations before the product is ready for application. Traditional machining is the broad term used to describe removal of material from a work piece, and covers chip formation operations including: turning, milling, drilling and grinding. Recently the industrial utilization of non-traditional machining processes such as EDM (electrical discharge machining), LBM (laser-beam machining), AWJM (abrasive water jet machining) and USM (ultrasonic machining) has increased. The performance characteristics of machine tools and the significant development of existing and new processes, and machines, are considered. Nowadays, in Europe, USA, Japan and countries with emerging economies machine tools is a sector with great technological evolution.
  • Includes high quality articles (full research articles, review articles and cases studies) with a special emphasis on research and development in machining and machine-tools
  • Considers the performance characteristics of machine tools and the significant development of existing and new processes and machines
  • Contains subject matter which is significant for many important centres of research and universities worldwide
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
Hard machining is a recent technology that can be defined as a direct machining operation of workpieces that have hardness values typically in the 45-70HRc range using tools with geometrically-defined cutting edges.

This operation always presents the challenge of selecting a cutting tool insert that facilitates an extended tool life and high-precision machining of the component. Hard machining presents several advantages when compared with the traditional methodology based on finish grinding operations after heat treatment of workpieces. This technology also offers a great contribution to sustainable manufacturing.

Hard materials comprise hardened steels, high-speed steels, heat-treatable steels, tool steels, bearing steels and chilled/white cast irons. Inconnel, Hastelloy, cobalt alloys for biomedical applications and other special materials are also classified as hard materials. These materials are in constant use by the automotive industry for bearing production and for the machining of dies and moulds as well as other components for advanced industries.

Machining of Hard Materials aims to provide the fundamentals and recent advances in the study of hard machining of materials. All chapters are written by international experts in this important field of research.

Chapter 1 defines machining of hard materials and its application in industry. Chapter 2 is dedicated to advanced cutting tools used for the machining of hard materials. Chapter 3 describes the mechanics of the cutting and chip formation. Chapter 4 contains information on surface integrity. Chapter 5 is dedicated to finite element modelling and simulation. Finally, Chapter 6 is dedicated to computational methods and optimization.

Machining of Hard Materials can serve as a useful reference for academics; manufacturing and materials researchers; manufacturing and mechanical engineers; and professionals in machining and related industries.

Machining processes play an important role in the manufacture of a wide variety of components. While the processes required for metal components are well-established, they cannot always be applied to composite materials, which instead require new and innovative techniques. Machining technology for composite materials provides an extensive overview and analysis of both traditional and non-traditional methods of machining for different composite materials.

The traditional methods of turning, drilling and grinding are discussed in part one, which also contains chapters analysing cutting forces, tool wear and surface quality. Part two covers non-traditional methods for machining composite materials, including electrical discharge and laser machining, among others. Finally, part three contains chapters that deal with special topics in machining processes for composite materials, such as cryogenic machining and processes for wood-based composites.

With its renowned editor and distinguished team of international contributors, Machining technology for composite materials is an essential reference particularly for process designers and tool and production engineers in the field of composite manufacturing, but also for all those involved in the fabrication and assembly of composite structures, including the aerospace, marine, civil and leisure industry sectors.
  • Provides an extensive overview of machining methods for composite materials
  • Chapters analyse cutting forces, tool wear and surface quality
  • Cryogenic machining and processes for wood based composites are discussed
The machining of complex sculptured surfaces is a global technological topic in modern manufacturing with relevance in both industrialized and emerging in countries particularly within the moulds and dies sector whose applications include highly technological industries such as the automotive and aircraft industry. Machining of Complex Sculptured Surfaces considers new approaches to the manufacture of moulds and dies within these industries. The traditional technology employed in the manufacture of moulds and dies combined conventional milling and electro-discharge machining (EDM) but this has been replaced with high-speed milling (HSM) which has been applied in roughing, semi-finishing and finishing of moulds and dies with great success.

Machining of Complex Sculptured Surfaces provides recent information on machining of complex sculptured surfaces including modern CAM systems and process planning for three and five axis machining as well as explanations of the advantages of HSM over traditional methods ranging from work piece precision and roughness to manual polishing following machining operations.

Whilst primarily intended for engineering students and post graduates (particularly in the fields of mechanical, manufacturing or materials), Machining of Complex Sculptured Surfaces provides clear instructions on modern manufacturing; serving as a practical resource for all academics, researchers, engineers and industry professionals with interest in the machining of complex sculptured surfaces.

Completely revised and updated, this second edition of Fundamentals of Machining Processes: Conventional and Nonconventional Processes covers the fundamentals machining by cutting, abrasion, erosion, and combined processes. The new edition has been expanded with two additional chapters covering the concept of machinability and the roadmap for selecting machining processes that meet required design specification.

See What’s New in the Second Edition:

  • Explanation of the definition of the relative machinability index and how the machinability is judged
  • Important factors affecting the machinability ratings
  • Machinability ratings of common engineering materials by conventional and nonconventional methods.
  • Factors to be considered when selecting a machining process that meets the design specifications, including part features, materials, product accuracy, surface texture, surface integrity, cost, environmental impacts, and the process and the machine selected capabilities
  • Introduction to new Magnetic Field Assisted Finishing Processes

    Written by an expert with 37 years of experience in research and teaching machining and related topics, this covers machining processes that range from basic conventional metal cutting, abrasive machining to the most advanced nonconventional and micromachining processes. The author presents the principles and theories of material removal and applications for conventional and nonconventional machining processes, discusses the role of machining variables in the technological characteristics of each process, and provides treatment of current technologies in high speed machining and micromachining.

    The treatment of the different subjects has been developed from basic principles and does not require the knowledge of advanced mathematics as a prerequisite. A fundamental textbook for undergraduate students, this book contains machining data, solved examples, and review questions which are useful for students and manufacturing engineers.

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