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| موضوع: كتاب Advanced Machining Processes - Nontraditional and Hybrid Machining Processes الخميس 11 أبريل 2013, 5:44 pm | |
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أخوانى فى الله أحضرت لكم كتاب Advanced Machining Processes Nontraditional and Hybrid Machining Processes Hassan El-Hofy Production Engineering Department Alexandria University, Egypt
و المحتوى كما يلي :
Contents Preface xi Acknowledgments xvii List of Acronyms xix List of Symbols xxiii Chapter 1. Material Removal Processes 1 1.1 Introduction 1 1.2 History of Machining 1 1.3 Traditional Machining 5 1.3.1 Machining by cutting 5 1.3.2 Machining by abrasion 6 1.4 Nontraditional Machining 8 1.4.1 Single-action nontraditional machining 9 1.4.2 Hybrid machining 10 References 13 Chapter 2. Mechanical Processes 15 2.1 Ultrasonic Machining 15 2.1.1 Introduction 15 2.1.2 The machining system 15 2.1.3 Material removal process 22 2.1.4 Factors affecting material removal rate 24 2.1.5 Dimensional accuracy and surface quality 26 2.1.6 Applications 28 2.2 Water Jet Machining 32 2.2.1 Introduction 32 2.2.2 The machining system 32 2.2.3 Process parameters 34 2.2.4 Applications 35 2.2.5 Advantages and disadvantages of WJM 38 2.3 Abrasive Jet Machining 39 2.3.1 Introduction 39 2.3.2 Machining system 39 2.3.3 Material removal rate 40 2.3.4 Applications 42 2.3.5 Advantages and limitations of AJM 42 For more information about this title, click hereviii 2.4 Abrasive Water Jet Machining 43 2.4.1 Introduction 43 2.4.2 The machining system 44 2.4.3 Process capabilities 45 2.5 Ice Jet Machining 46 2.5.1 Introduction 46 2.5.2 Process description 46 2.6 Magnetic Abrasive Finishing 48 2.6.1 Introduction 48 2.6.2 The machining system 48 2.6.3 Material removal process 49 2.6.4 Applications 50 References 52 Chapter 3. Chemical Processes 55 3.1 Chemical Milling 55 3.1.1 Introduction 55 3.1.2 Tooling for CHM 57 3.1.3 Process parameters 61 3.1.4 Material removal rate 61 3.1.5 Accuracy and surface finish 62 3.1.6 Advantages 63 3.1.7 Limitations 64 3.1.8 Applications 64 3.2 Photochemical Milling 66 3.2.1 Introduction 66 3.2.2 Process description 66 3.2.3 Applications 67 3.2.4 Advantages 68 3.3 Electropolishing 70 3.3.1 Introduction 70 3.3.2 Process parameters 73 3.3.3 Applications 73 3.3.4 Process limitations 74 References 75 Chapter 4. Electrochemical Processes 77 4.1 Electrochemical Machining 77 4.1.1 Introduction 77 4.1.2 Principles of electrolysis 77 4.1.3 Theory of ECM 78 4.1.4 ECM equipment 79 4.1.5 Basic working principles 84 4.1.6 Process characteristics 87 4.1.7 Process control 95 4.1.8 Applications 97 4.1.9 Micro-ECM 98 4.1.10 Advantages and disadvantages of ECM 98 4.1.11 Environmental impacts 99 4.2 Electrochemical Drilling 100 4.3 Shaped Tube Electrolytic Machining 102 Contentsix 4.4 Electrostream (Capillary) Drilling 105 4.5 Electrochemical Jet Drilling 108 4.6 Electrochemical Deburring 109 References 112 Chapter 5. Thermal Processes 115 5.1 Electrodischarge Machining 115 5.1.1 Introduction 115 5.1.2 Mechanism of material removal 115 5.1.3 The machining system 120 5.1.4 Material removal rates 125 5.1.5 Surface integrity 127 5.1.6 Heat-affected zone 129 5.1.7 Applications 130 5.1.8 Process control 137 5.1.9 EDM automation 138 5.1.10 Environmental impact 139 5.2 Laser Beam Machining 140 5.2.1 Introduction 140 5.2.2 Material removal mechanism 141 5.2.3 Applications 144 5.2.4 Advantages and limitations 156 5.3 Electron Beam Machining 157 5.3.1 Introduction 157 5.3.2 Basic equipment and removal mechanism 157 5.3.3 Applications 163 5.3.4 Advantages and disadvantages 165 5.4 Plasma Beam Machining 166 5.4.1 Introduction 166 5.4.2 Machining systems 166 5.4.3 Material removal rate 169 5.4.4 Accuracy and surface quality 169 5.4.5 Applications 171 5.4.6 Advantages and disadvantages 172 5.5 Ion Beam Machining 172 5.5.1 Introduction 172 5.5.2 Material removal rate 173 5.5.3 Accuracy and surface effects 175 5.5.4 Applications 176 References 177 Chapter 6. Hybrid Electrochemical Processes 181 6.1 Introduction 181 6.2 Electrochemical Grinding 182 6.2.1 Introduction 182 6.2.2 Material removal rate 183 6.2.3 Accuracy and surface quality 187 6.2.4 Applications 188 6.2.5 Advantages and disadvantages 188 6.3 Electrochemical Honing 189 6.3.1 Introduction 189 6.3.2 Process characteristics 189 Contents ix6.3.3 Applications 191 6.4 Electrochemical Superfinishing 192 6.4.1 Introduction 192 6.4.2 Material removal process 193 6.4.3 Process accuracy 195 6.5 Electrochemical Buffing 196 6.5.1 Introduction 196 6.5.2 Material removal process 196 6.6 Ultrasonic-Assisted ECM 197 6.6.1 Introduction 197 6.6.2 Material removal process 198 6.7 Laser-Assisted ECM 199 References 201 Chapter 7. Hybrid Thermal Processes 203 7.1 Introduction 203 7.2 Electroerosion Dissolution Machining 204 7.3 Electrodischarge Grinding 212 7.4 Abrasive Electrodischarge Machining 216 7.5 EDM with Ultrasonic Assistance 218 7.6 Electrochemical Discharge Grinding 221 7.7 Brush Erosion-Dissolution Mechanical Machining 224 References 226 Chapter 8. Material Addition Processes 229 8.1 Introduction 229 8.2 Liquid-Based Techniques 230 8.2.1 Stereolithography 230 8.2.2 Holographic interference solidification 232 8.2.3 Beam interference solidification 232 8.2.4 Solid ground curing 233 8.2.5 Liquid thermal polymerization 235 8.2.6 Fused deposition modeling 235 8.2.7 Multijet modeling 238 8.2.8 Ballistic particles manufacturing 239 8.2.9 Shape deposition manufacturing 240 8.3 Powder-Based Processes 241 8.3.1 Selective laser sintering 241 8.3.2 Laser engineered net shaping 242 8.3.3 Three-dimensional printing 243 8.4 Solid-Based Techniques 244 8.4.1 Solid foil polymerization 244 8.4.2 Laminated object modeling 245 References 246 Index 249 Index Abrasive machining: conglomerates, 48, 49 electrodischarge machining, 203, 216 flow machining, 109 grain, 6, 15, 21, 22, 24, 25, 39, 49, 50, 184–186, 194, 198, 215, 216 grit, 29, 183, 189 jet machining, 34, 49 slurry, 9, 16, 17, 21, 24–28, 109, 218 water jet machining, 9, 43, 54, 145 Accuracy: of ECM, 90 levels, 26, 175, 246 of machined parts, 26, 90 Air plasma, 167, 168, 169, 180 Anodic dissolution, 12, 71, 72, 74, 81, 101, 102, 222, 223 Anodic film, 72 Anodic workpiece, 77, 78, 102, 103, 106, 108, 182, 183, 185 Aspect ratio, 104, 146, 148, 154, 155 Back pressure, 83, 101 Ballistic particles manufacturing, 239, 243 Beam interference solidification, 232, 248 Brass, 15, 23, 54, 73, 84, 121, 123, 144, 153 Brush erosion-dissolution mechanical machining, 224 Capillary drilling, 105, 108, 109 Cast iron, 82, 95 Cathode, 71, 72, 78, 79, 81, 83, 99, 103, 116–118, 152, 160, 166, 172, 173, 182, 196 Cathodic reactions, 77 Cathodic tool, 78, 83, 87, 93, 100, 102, 103, 105, 106, 183, 189, 190, 192, 198 Ceramics, 6, 8, 35, 39, 41–43, 52, 65, 67, 131, 133, 134, 140, 144, 156,177–179, 197, 201, 214, 229, 239, 242, 245 Chemical blanking, 10, 66 Chemical dissolution, 10–12, 55, 62, 181, 182 Chemical etching, 176, 181 Chemical milling, 10, 55, 56, 66 Chemical processes, 12, 55 Chromium, 21, 37, 144, 150, 162, 175 Composites, 8, 43, 133, 149, 150, 178, 188, 201, 204, 214, 226, 229, 245 Computer-aided design, 46, 66 Computer-integrated manufacturing, 83, 130, 138 Computer keyboard, 154, 179 Computer numerical control, 3, 31, 132, 171 Constant current, 90, 91, 96, 97, 112 Constant feed, 80, 85, 86, 96 Constant gap, 85, 96, 119, 120 Continuous wave, 140 Contour machining, 29, 30, 53 Copper, 21, 38–40, 58, 64, 67, 71, 73, 82, 84, 88, 111, 121, 123, 126, 135, 136, 144, 153, 155, 166, 168, 169, 176, 186, 187, 232, 243 Coring, 28 Crater, 27, 118, 125, 126–128, 134, 151, 152, 203, 206, 208–210, 221, 223 Cubic boron nitride, 133 Current: density, 71, 72, 73, 82, 84, 88–95, 118, 175, 181, 183, 186, 187, 189, 194–196, 199, 200, 208, 209, 213, 223 249 Copyright 2005 by The McGraw-Hill Companies, Inc. Click here for terms of use.Current: (Conti.) efficiency, 82–85, 89, 90, 102, 200 flow, 96, 97, 112, 118, 196 lines, 185, 194 Cutting: of printed circuit boards, 38 rate, 34–36, 41, 45, 46, 146, 168, 169 of rocks, 37 speed, 43, 121, 143, 149, 153, 166, 171, 172 DC power supply, 72, 81, 183, 193, 195, 198, 205, 213, 215, 217–219, 222, 224 Deburring, 37, 40, 42, 44, 52, 74, 79, 97, 99, 109–112, 172 Dielectric fluid, 118, 121, 123, 124, 212, 220, 226 Dielectric flushing, 124, 131, 203, 214 Dielectric liquid, 103, 203 Dielectric type, 134 Die sinking, 91, 99, 115, 131, 132, 139, 140, 226 Dies and molds, 128, 131, 204 Dissolution phase, 10, 181, 194, 195, 197–199, 203, 210, 223 Dressing of grinding wheels, 152, 179 Dynamic balancing, 155 ECD phase, 87, 184, 189, 191, 193, 200, 203, 212, 222, 223 ECG process, 184–186, 188, 201 ECM: accuracy, 92 equipment, 79 process, 87, 97 EDE phase, 12, 116, 203, 207, 209, 214, 216, 217, 219, 222, 225 EDM: automation, 138 dielectric, 120, 123 electrodes, 30, 121, 232 milling, 131–133 with ultrasonic assistance, 218 EEDM wire cutting, 205 Electrochemical processes: arc machining, 203, 226 buffing, 12, 182, 196, 201 deburring, 109, 111 discharge grinding, 13, 203, 221 discharge machining, 203 dissolution, 10, 11, 27, 100, 181, 183, 184, 186, 196, 198, 201, 203, 221, 224, 226 drilling, 91, 100, 145 grinding, 11, 181, 182, 184 honing, 181, 189, 201 jet drilling, 108 machining, 10–12, 75, 77, 78, 88, 97, 112, 113, 145,181, 182, 197, 199, 201, 204, 208, 226 superfinishing, 12, 181, 192 Electrode: material, 121–123, 132, 224, 225 polarity, 121, 125, 134 wear, 121, 122, 131, 220 Electrodischarge: erosion, 12, 115, 203, 206, 221, 224 grinding, 136, 203, 212, 214, 226 machining, 9, 10, 15, 130, 145, 177, 203, 204, 216,220, 227 texturing, 128, 134 Electroerosion dissolution machining, 203, 204 Electrolysis, 77, 79, 101, 102, 110, 206, 209 Electrolyte: concentration, 82, 90, 95 feeding, 79, 83, 96, 101 flow rate, 90, 92, 95, 101, 196, 201, 206 type, 92, 103, 194, 196 velocity, 95, 208 Electrolyzing current, 78, 84 Electron beam machining, 9, 157, 160, 179 Electropolishing, 70–75 Electrostream drilling, 106, 108 Environmental impacts, 46, 99 Equilibrium gap, 86, 87 Erosion phase, 206, 222, 223 Etch factor, 56–58, 60, 61 Etch rate, 58, 61–63, 174 Etchant, 10, 12, 57–60, 63, 66, 67, 70 Evaporation, 118, 143, 152, 154, 158, 203, 218, 223 Faraday’s laws, 77, 85, 88, 101, 110, 184 Feed rate, 35–37, 40, 45, 46, 80, 83, 84, 86, 87, 90, 93, 95–97, 100, 101–105, 112, 130, 171, 186–188, 208–210, 223, 224, 243 Fiber-reinforced plastics, 34, 36, 37, 155 Flushing, 12, 22, 115, 118, 120, 121, 123–125, 178, 182, 203, 209, 214, 219, 220, 226 Fused deposition modeling, 235, 237, 244 Gap: pressure, 96, 101, 208 short circuit, 87, 208, 220 250 Indexvoltage, 81, 83, 85, 90, 95, 96, 102, 106, 113, 119, 137, 183, 184, 189, 194, 208, 219, 220, 224 width, 90, 92, 93, 115, 119, 183, 186, 205 Graphite, 23, 27, 30, 31, 36, 47, 95, 121–123, 126, 128, 135, 152, 211, 213, 214, 218, 228 Grinding: action, 187, 221 process, 184 stick, 194 wheels, 7, 152, 179, 186 Grooving, 149, 151, 177, 179 Heat-affected zone, 9, 35, 70, 118, 129, 150, 162, 171, 213 History of machining, 1 Holographic interference solidification, 232 Hybrid electrochemical processes, 182 Hybrid thermal machining, 11, 12, 203, 204 Hydraulic pump, 32 Hydrogen, 59, 64, 79, 99, 101, 168 Ice jet machining, 9, 46, 52 Ignition delay, 117, 210, 220 Insulating ceramics, 133, 134, 179 Integrated circuit, 65, 163, 164 Intensifier, 32, 33, 44 Ion beam machining, 3, 4, 9, 172, 174 Iron, 1, 49, 78, 79, 82, 95, 161 Jet: cutting nozzle, 33 diameter, 34, 41, 46, 108 machining, 9, 32, 34, 35, 39, 41, 43, 46, 52, 145 velocity, 33, 34, 41 Laminated object modeling, 245 Laser-assisted electrochemical machining, 11, 181, 199 Laser beam: drilling, 147 machining, 9, 140, 144, 146 texturing, 151 Liquid-based techniques, 230 Liquid thermal polymerization, 235 Machinability, 4, 6, 23, 75, 83, 89–92, 104, 113, 143, 144, 160–162, 169, 170, 174, 177, 178, 186, 187, 201, 210, 211, 223, 226 Machining: by abrasion, 6 by cutting, 5, 6, 13, 52, 113, 178, 201 of fiber-reinforced plastics, 36 of spheres, 131 system, 15, 16, 32, 39, 44, 46, 48, 50, 102, 120, 135, 166, 167, 172, 183, 189, 190, 198, 204, 205, 215, 218 Magnetic finishing of: balls, 50 magnetic tubes, 50 nonmagnetic tubes, 51 rollers, 52 Magnetostrictor, 15–21 MA phase, 185, 222, 225 Maskant, 55, 57–59, 61 Mechanical abrasion, 5, 9–12, 22, 39, 50, 181, 184–186, 189, 190, 193, 194, 197–199, 203, 214, 221–223 Mechanical amplifier, 15, 20 Mechanical machining, 9, 10, 12, 181, 203, 224, 226 Mechanical pulse electrodischarge machining, 220, 227 Mechanism of material removal, 115, 172, 174 Metallic bond, 183, 185, 189, 192, 193, 214, 215 Metal matrix composites, 149, 178 Micro-ECM, 98, 137, 155, 177 Micro-EDM, 135 Micromachining, 4, 13, 74, 113, 122, 130, 155, 157, 178, 201, 246 Micro ultrasonic machining, 31, 52 Multijet modeling, 238 Nickel, 21, 58, 61, 62–64, 67, 73, 82, 88, 89, 91, 144, 162, 169, 176 187 Nitric acid, 103 Nontraditional machining, 5, 8, 9, 11, 229 Numerical control, 3, 29, 31, 132, 171 Overcut, 26, 80, 83, 100, 101, 103, 108, 130, 186, 187, 214 Oxide film, 89, 90, 102, 185, 193–195, 197 Oxygen, 39, 71, 79, 128, 148–150, 168, 169, 178, 210, 226, 243 Passivation, 12, 85, 90–92, 95, 96, 181, 198, 201, 223 Photochemical milling, 59, 66 Photoresist, 59, 66–68, 175 Index 251Plasma: arc, 166, 167, 169, 171, 172 beam, 9, 166, 169, 170 channel, 118, 119, 135, 216, 218, 220 jet, 166–169 Polishing, 4, 5, 7, 30, 31, 38, 39, 42, 48, 50–52, 70–75, 91, 109, 128, 172, 176, 196, 218 Powder-based processes, 241 Printed circuit boards, 34, 38, 52 Process: accuracy, 26, 90, 95, 101, 195 capabilities, 45, 104, 106, 158 characteristics, 41, 42, 87, 189 control, 95, 137 description, 46, 66 parameters, 34, 61, 73, 103, 113, 114, 165, 184, 198 Pulse: charge, 161, 162 current, 97, 98, 116, 120, 126–128, 134, 135, 206 duration, 127, 138, 142, 146–148, 154, 160, 161, 163, 209 electrochemical machining, 113, 208 energy, 126–128, 147, 148, 161, 162, 210, 223 frequency, 160, 165, 209, 214 on-time, 120, 127 Pulsed power supply, 221 Rapid prototyping, 229, 232, 235, 240, 246 Recast layer, 35, 65, 104, 118, 129, 131, 146, 166, 204 Resolidified layer, 129, 152 Rotary ultrasonic machining, 28, 52 Sapphire, 28, 33, 34, 41, 42 Sawing, 5, 130, 188 Scribing template, 57, 60 Selective laser sintering, 230, 241, 243 Servo controlled feed, 121, 213, 215 Shape deposition manufacturing, 240 Shaped tube electrolytic machining, 102 Shielded plasma, 167–170 Short circuit, 80, 81, 87, 90, 119, 208, 209, 218, 220 Shot blasting, 134, 151 Slotting, 159, 160, 163 Slurry injection methods, 22 Smoothing, 12, 66, 71, 74, 75, 175, 176, 197 Sodium chloride, 78, 81, 82, 189 Sodium nitrate, 81, 82, 189 Solid-based processes, 230 Solid foil polymerization, 244 Solid free-form fabrication, 229, 240 Solid ground curing, 233 Spark: erosion, 132, 226 gap, 135, 212 machining, 178, 179, 226 Standoff distance, 34, 37, 40, 41, 45 Steels, 1, 35, 61, 62, 95, 106, 111, 168, 169, 186, 187, 218, 226 Stereolithography, 230, 231, 235, 242 Surface: effects, 175 formation, 93, 208 integrity, 4, 127, 186, 226 quality, 1, 2, 8–10, 12, 24, 26, 27, 35, 37, 46, 50, 62, 64, 73, 83, 92, 93, 95, 99, 101, 123, 125, 160, 162, 169, 181, 187, 188, 197, 199, 206, 209 reflectivity, 147, 165 roughness, 27, 30, 36, 41, 42, 45, 62, 63, 71, 73, 93–95, 111, 126–128, 131, 135, 162, 165, 177, 190, 195, 206, 209, 210, 213, 218, 220, 221, 223 treatment, 38, 43, 177 Texturing, 38, 53, 128, 130, 134, 135, 151, 175, 177, 178, 179 Theory of ECM, 78 Thermal energy method, 109 Thermal properties,125, 143, 146, 160, 161 Thermal machining, 9, 11, 12, 203, 204, 227 Thinning of parts, 65 Three-dimensional printing, 243, 244, 246 Titanium, 23, 39, 58, 59, 61–65, 67, 82, 84, 90, 91, 103, 106, 107, 143, 144, 161, 187, 188, 218, 243 Tool: design, 83, 96, 113, 138 electrode, 97, 99, 103, 110, 113, 115, 119, 121 feed rate, 83, 95–97, 102, 103 insulation, 84, 90, 101, 111 material, 1, 23, 27, 31, 121, 122, 208 oscillation, 24, 27, 192, 198, 206 shape, 15, 25, 83, 97 wear, 6, 13, 27, 74, 118, 119, 122, 136, 155, 156, 177, 184, 199, 220, 224 252 IndexTooling for CHM, 57 Traditional machining, 5, 8, 35, 67,138, 218 Traditional grinding, 187 Trimming of electronic components, 154 Tungsten, 21, 23, 26, 39, 42, 82, 84, 91, 113, 121, 123, 136, 157, 161, 162, 166, 168, 172, 187, 188, 216, 218 Turbine blade, 29, 104, 106, 130, 163 Turning, 3, 5–7, 83, 99, 112, 138, 139, 151, 167, 169–171 Ultrasonic accuracy, 26 Ultrasonic-assisted electrochemical machining, 12, 181, 197 Ultrasonic contour machining, 53 Ultrasonic machining, 9, 12, 15, 28, 31, 52, 145, 197, 218 Ultrasonic machining system, 16 Ultrasonic polishing, 30, 31 Ultrasonic sinking, 29 Ultrasonic vibration, 22, 28, 124, 203, 218–220, 227 Vaporization, 109, 134, 141, 142 Volumetric removal rate, 41, 88, 126, 142, 159, 184, 208, 210 Wire: cutting, 132, 140, 204, 205, 209, 226 EDM, 43, 104, 106, 115, 132, 133, 136, 140, 178 electrodischarge grinding, 136 stripping, 38 Workpiece: impact hardness, 25 material, 4, 6, 9, 12, 15, 23, 26, 32, 38, 39, 43, 45, 49, 55, 58, 61, 63, 73, 81, 82, 99, 121, 125, 126, 129, 135, 143, 145, 151, 159, 160, 161, 169, 170, 175, 179, 184, 196, 203, 213, 223 shape, 83, 122 Index 253
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