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عدد المساهمات : 19002 التقييم : 35506 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: كتاب Machining - Fundamentals and Recent Advances الأحد 23 أغسطس 2020, 11:37 pm | |
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أخوانى فى الله أحضرت لكم كتاب Machining - Fundamentals and Recent Advances J. Paulo Davim Editor
و المحتوى كما يلي :
Contents 1 Metal Cutting Mechanics, Finite Element Modelling 1 Viktor P. Astakhov and José C. Outeiro 1.1 Advanced Metal Cutting Mechanics . 1 1.1.1 Objective of Metal Cutting Mechanics 1 1.1.2 State of the Art . 1 1.1.3 Advanced Methodology . 4 1.1.4 Combined Influence of the Minor Cutting Edge 7 1.1.5 Influence of the Cutting Speed, Depth of Cut and Cutting Feed on Power Partition . 9 1.1.6 Concluding Remarks 11 1.2 Finite Element Analysis (FEA) . 13 1.2.1 Numerical Formulations 14 1.2.2 Modelling Chip Separation from the Workpiece and Chip Segmentation 15 1.2.3 Mesh Design 16 1.2.4 Work Material Modelling 18 1.2.5 Modelling of Contact Conditions . 19 1.2.6 Numerical Integration 19 1.2.7 Errors . 20 1.2.8 Example . 20 1.2.9 Advanced Numerical Modelling 21 1.2.10 Model Validation . 22 References . 25viii Contents 2 Tools (Geometry and Material) and Tool Wear . 29 Viktor P. Astakhov and J. Paulo Davim 2.1 Essentials of Tool Geometry . 29 2.1.1 Importance of the Cutting Tool Geometry . 29 2.1.2 Basic Terms and Definitions 31 2.1.3 System of Considerations . 32 2.1.4 Basic Tool Geometry Components 33 2.1.5 Influence of the Tool Angles 35 2.2 Tool Materials . 37 2.2.1 Carbides . 39 2.2.2 Ceramics 43 2.2.3 Cubic Boron Nitride (CBN) . 44 2.2.4 Polycrystalline Diamond (PCD) and Solid Film Diamond (SFD) . 45 2.3 Tool Wear 48 2.3.1 Tool Wear Types 48 2.3.2 Tool Wear Evolution 50 2.3.4 Mechanisms of Tool Wear . 52 2.4 Tool Life 52 2.4.1 Taylor’s Tool Life Formula . 53 2.4.2 Expanded Taylor’s Tool Life Formula . 55 2.4.3 Recent Trends in Tool Life Evaluation 55 References . 57 3 Workpiece Surface Integrity 59 Joël Rech, Hédi Hamdi and Stéphane Valette 3.1 What Does Surface Integrity Mean? 59 3.1.1 Link Between Surface Integrity and its Manufacturing Procedure . 62 3.1.2 Impact of the Surface Integrity on the Dimensional Accuracy 64 3.1.3 Impact of the Surface Integrity on Fatigue Resistance . 67 3.2 Material and Mechanical Aspects of Surface Integrity 68 3.2.1 Mechanisms Leading to Material and Mechanical Modifications in Machining . 68 3.2.2 Modelling of Residual Stresses 74 3.2.3 Experimental Approach . 80 References . 91Contents ix 4 Machining of Hard Materials 97 Wit Grzesik 4.1 Basic Features of HM 97 4.1.1 Definition of Hard Machining 97 4.1.2 Comparison with Grinding Operations 98 4.1.3 Technological Processes Including Hard Machining . 100 4.2 Equipment and Tooling . 101 4.2.1 Machine Tools . 101 4.2.2 Cuting Tools and Materials 102 4.2.3 Complete Machining Using Hybrid Processes . 104 4.3 Characterization of Hard Machining Processes . 105 4.3.1 Cutting Forces 105 4.3.2 Chip Formation 105 4.3.3 Cutting Temperature 108 4.3.4 Wear of Ceramic and PCBN Tools 110 4.3.5 Modelling of Hard Cutting Processes 110 4.4 Surface Integrity in Hard Machining Processes 113 4.4.1 Surface Roughness . 113 4.4.2 Residual Stresses 114 4.4.3 Micro/Nanohardness Distribution and White-Layer Effect 115 4.4.4 Modification of Surface Finish in Hybrid Processes 117 4.4.5 Cutting Errors and Dimensional Accuracy 118 4.5 Applications of Hard Machining Processes . 119 4.5.1 Hard Turning 119 4.5.2 Hard and High-Speed Milling of Dies and Moulds . 120 4.5.3 Hard Reaming 121 4.5.4 Hard Broaching 122 4.5.5 Hard Skive Hobbing . 122 4.5.6 Optimization of Hard Machining Processes . 123 References . 124 5 Machining of Particulate-Reinforced Metal Matrix Composites . 127 A. Pramanik, J.A. Arsecularatne and L.C. Zhang 5.1 Introduction . 127 5.2 Effect of Reinforcement Particles on Surface Integrity and Chip Formation . 129 5.2.1 Strength of MMC During Machining . 130 5.2.2 Chip Shape . 131x Contents 5.2.3 Surface Integrity . 135 5.2.4 Shear and Friction Angles 142 5.2.5 Relation Between Shear and Friction Angles . 144 5.2.6 Forces . 145 5.3 Modelling 147 5.3.1 Forces . 147 5.3.2 Tool–Particle Interaction 157 5.4 Tool Wear 159 5.4.1 Performance of Cutting Tools 159 5.4.2 Modelling of Tool Wear 161 Acknowledgements . 162 References . 162 6 Drilling Polymeric Matrix Composites . 167 Edoardo Capello, Antonio Langella, Luigi Nele, Alfonso Paoletti, Loredana Santo, Vincenzo Tagliaferri 6.1 Introduction . 167 6.1.1 What Are Polymeric Matrix Composites? . 167 6.1.2 The Importance of Drilling 171 6.2 Drilling Technology of Polymeric Matrix Composites . 173 6.2.1 Conventional Drilling Process . 173 6.2.2 Unconventional Drilling Processes 178 6.3 Modelling of Conventional Drilling 179 6.3.1 The Need for Modelling . 179 6.3.2 Cutting Force Modelling 180 6.4 Damage Generated During Drilling and Residual Mechanical Properties 183 6.4.1 Structural Damage 183 6.4.2 Residual Mechanical Properties . 186 6.5 Damage Suppression Methods 188 6.5.1 Introduction 188 6.5.2 Process Parameters Selection . 188 6.5.3 Drilling Conditions 189 6.5.4 Special Tools 190 References . 191 7 Ecological Machining: Near-dry Machining 195 Viktor P. Astakhov 7.1 Introduction . 195 7.2 Amount and Cost . 196 7.3 Health and Environmental Aspects . 197 7.4 Principal Directions in the Reduction of MWF Economical, Ecological and Helth Impacts 198Contents xi 7.5 Nearly Dry Machining (NDM) 201 7.5.1 How NDM Operates 201 7.5.2 Classification of NDM . 202 7.5.3 Why NDM Works 212 7.5.4 Consideration of the NDM System Components . 217 References . 221 8 Sculptured Surface Machining 225 L. Norberto L?pez de Lacalle and A. Lamikiz 8.1 Introduction . 225 8.2 The Manufacturing Process . 227 8.2.1 Technologies Involved . 228 8.3 The CAM, Centre of Complex Surfaces Production . 231 8.4 Workpiece Precision 233 8.4.1 Cutting Forces 235 8.5 Workpiece Roughness . 237 8.6 Tool Path Selection Using Cutting Force Prediction . 239 8.6.1 Three-axis Case 240 8.6.2 Five-axis Case 241 8.7 Examples . 242 8.7.1 Three-axis Mould . 242 8.7.2 Five-axis Mould . 243 8.7.3 Three-axis Deep Mould . 245 8.8 Present and Future . 246 Acknowledgements . 246 References . 247 9 Grinding Technology and New Grinding Wheels 249 M.J. Jackson 9.1 Introduction . 249 9.2 High-efficiency Grinding Using Conventional Abrasive Wheels . 250 9.2.1 Introduction 250 9.2.2 Grinding Wheel Selection 251 9.2.3 Grinding Machine Requirements for High-efficiency Dressing 253 9.2.4 Diamond Dressing Wheels . 253 9.2.5 Application of Diamond Dressing Wheels . 256 9.2.6 Modifications to the Grinding Process . 257 9.2.7 Selection of Grinding Process Parameters . 257 9.2.8 Selection of Cooling Lubricant Type and Application . 258 8.2.2 Five-axis Milling 229xii Contents 9.3 High-efficiency Grinding Using CBN Grinding Wheels . 258 9.3.1 Introduction 258 9.3.2 Grinding Wheel Selection 259 9.3.3 Grinding Machine Requirements for High-efficiency CBN Grinding 264 9.3.4 Dressing High-efficiency CBN Grinding Wheels 265 9.3.5 Selection of Dressing Parameters for High-efficiency CBN Grinding 266 9.3.6 Selection of Cooling Lubrication for High-efficiency CBN Grinding Wheels . 266 9.4 Internet Resources . 267 References . 269 10 Micro and Nanomachining 271 M.J. Jackson 10.1 Introduction . 271 10.2 Machining Effects at the Microscale . 272 10.2.1 Shear Angle Prediction 275 10.2.2 Plastic Behaviour at Large Strains . 278 10.2.3 Langford and Cohen’s Model 278 10.2.4 Walker and Shaw’s Model . 279 10.2.5 Usui’s Model 280 10.2.6 Saw-tooth Chip Formation in Hard Turning . 281 10.2.7 Fluid-like Flow in Chip Formation . 281 10.3 Size Effects in Micromachining 282 10.4 Nanomachining 282 10.4.1 Nanometric Machining 283 10.4.2 Theoretical Basis of Nanomachining . 284 10.4.3 Comparison of Nanometric Machining and Conventional Machining . 294 Acknowledgements . 295 References . 295 11 Advanced (Non-traditional) Machining Processes . 299 V.K. Jain 11.1 Introduction . 299 11.2 Mechanical Advanced Machining Processes (MAMP) . 301 11.2.1 Ultrasonic Machining (USM) 301 11.2.2 Abrasive Water Jet Cutting (AWJC) 304 11.3 Thermoelectric Advanced Machining Processes . 307 11.3.1 Electric Discharge Machining (EDM) and Wire EDM 307 11.3.2 Laser Beam Machining (LBM) 312Contents xiii 11.4 Electrochemical Advanced Machining Processes . 313 11.4.1 Electrochemical Machining (ECM) . 313 11.4.2 ECM Machine 315 11.5 Fine Finishing Processes . 317 11.5.1 Abrasive Flow Machining (AFM) . 317 11.5.2 Magnetic Abrasive Finishing (MAF) . 320 11.5.3 Magnetic Float Polishing (MFP) 323 11.6 Micromachining 324 11.7 Finished Surface Characteristics 325 References . 325 12 Intelligent Machining: Computational Methods and Optimization 329 Sankha Deb and U.S. Dixit 12.1 Intelligent Machining 329 12.2 Neural Network Modelling 332 12.3 Fuzzy Set Theory . 339 12.4 Neuro-fuzzy Modelling . 344 12.5 A Note on FEM Modelling 347 12.6 Machining Optimization 348 12.6.1 Objective Functions and Constraints . 348 12.6.2 Optimization Techniques . 350 12.7 Future Challenges 355 References . 356 Index Index Abrasive flow machining (AFM) 317 Abrasive water jet cutting (AWJC) 304 Abrasive wheels CBN 258 conventional 250 Advanced metal cutting mechanics 1 methodology 4 non-traditional machining 299 numerical modelling 21 Aerosol composition 208 supply 202 Carbides 39 Ceramics 43 Chip formation 105, 129, 281 management 219 Coating 40 Computational methods and optimization 329 Computer-assisted manufacturing (CAM) 231 Cooling lubricant 258 Cubic boron nitride (CBN) 44 Cutting forces 105, 145 forces prediction 239 temperature 108 tools 159 Damage evaluation methods 183 structural 183 suppression methods 188 Delamination 184 Dies and moulds five-axis 243 high-speed milling 120 three-axis 242 three-axis deep 245 Dressing diamond 256 high efficiency 265 Drilling conditions 189 conventional process 173 unconventional processes 178 Ecological machining 195 Electro-chemical machining 313 Electro-discharge machining (EDM) 307360 Index Fine finishing processes 317 Finished surface characteristics 325 Finite element analysis 13 Finite element modelling 1 Friction angles 142, 144 Fuzzy set theory 339 Genetic algorithms 353 Grinding 249 high efficiency 250, 258, 264–266 process parameters 257 wheels 249, 258, 265, 266 Hard broaching 122 machining (HM) 97, 100, 105, 113, 123 reaming 121 skive hobbing 122 turning 86, 119 Hardness 115, 141 Hole manufacturing 91 Intelligent machining 329 Laser beam machining (LBM) 312 Machine tools 101 Machining conventional 294 effects of the microscale 272 electro-chemical advanced 313 hard materials 97 hybrid processes 104 nanometric 294 optimization 348 thermo-electric advanced processes 307 Magnetic abrasive finishing (MAF) 320 Magnetic float polishing (MFP) 323 Manufacturing process 227 Mesh design 16 Metal cutting mechanics 1 Metal matrix composites (MMCs) 127, 130 Method golden section search 350 sequential quadratic programming (SQP) 352 Micromachining 271, 282, 324 Milling, five-axis 229 Minor cutting edge 7 Model Langford and Cohen 278 Usui 280 validation 22 Walker and Shaw 279 Modelling chip segmentation 15 chip separation 15 contact conditions 19 conventional drilling 179 delamination 185 forces 147 hard cutting process 110 neural network 332 neuro-fuzzy 344 residual stresses 74 tool wear 161 Nanomachining 271, 282, 284 Near-dry machining (NDM) 195 classification 202 system components 217 Numerical formulations 14 integration 19 Optimization hard machining processes 123 techniques 350 Polycrystalline diamond (PCD) 45 Polymeric matrix composites (PMCs) 167Index 361 Residual mechanical properties 183, 186, 187 Residual stresses 114, 139 Sculptured machining 225 Shear, angle prediction 275 Special tools 190 Super-finishing 89, 117 Surface integrity 59, 113, 129, 135 Surface roughness 113, 135 Taylor’s tool life expanded formula 55 formula 53 Thermal effects with microstructural changes 71 without microstructural changes 71 Thrust force 175 Tool angles 35 life 52 life evaluation 55 materials 37 wear 29, 48, 159 wear evolution 50 wear mechanisms 52 wear types 48 Tool path five-axis 241 three-axis 240 Tools geometry 29 material 37 Torque 177 Ultrasonic machining (USM) 301 White layer 115 Workpieces precision 233 roughness 239 surface integrity 59
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