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Manufacturing is the basic industrial activity generating real value. Cutting and abrasive technologies are the backbone of precision production in machine, automotive and aircraft building as well as of production of consumer goods. We present the knowledge of modern manufacturing in these technologies on the basis of scientific research. The theory of cutting and abrasive processes and the knowledge about their application in industrial practice are a prerequisite for the studies of manufacturing science and an important part of the curriculum of the master study in German mechanical engineering. The basis of this book is our lecture “Basics of cutting and abrasive processes” (4 semester hours/3 credit hours) at the Leibniz University Hannover, which we offer to the diploma and master students specializing in manufacturing science.
This new edition draws upon the fundamentals of abrasive machining processes and the science of tribology to understand, predict, and improve abrasive machining processes. Each of the main elements of the abrasive machining system is looked at alongside the tribological factors that control the efficiency and quality of the processes described. The new edition has been updated to include a variety of industrial applications. Grinding and conditioning of grinding tools are dealt with in particular detail, and solutions are proposed for many of the most commonly experienced industrial problems, such as poor accuracy, poor surface quality, rapid tool wear, vibrations, workpiece burn, and high process costs. The entire book has been rewritten and restructured, with ten completely new chapters. Other new features include: Extensive explanations of the main abrasive machining processes such as grinding (including reciprocating and creep-feed grinding, high-speed high-efficiency deep grinding, external and internal cylindrical grinding, and centerless grinding), honing, superfinishing, lapping, polishing, and finishing Discussions of the new classes of abrasives, abrasive tools, and bonding materials New case studies and troubleshooting on the most common grinding practices New coverage on grinding tool conditioning, mechanical dressing, and nonmechanical dressing processes Detailed explanations of the effects of process input parameters (such as cutting parameters, workpiece material and geometry, and abrasive tools) on process characteristics, workpiece quality, tool wear, and process parameters (such as cutting forces and temperature as well as achievable material removal rate) Updated topics regarding process fluids for abrasive machining and fluid delivery
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.
Abrasive water jet machining was introduced to manufacturing ten years ago and has been increasingly used for treating hard-to-machine and multi-layered materials and as an alternative tool for milling, turning, drilling and polishing. This is the first comprehensive review of the technique, dealing with a broad range of issues including mixing and acceleration processes, material removal mechanisms, process optimization and fluid mechanics. Explanations are given as the book follows the development of an abrasive water jet machining process, from tool generation through to machining results, supervision and control. This methodical journey through the field is marked by drawings, graphs and tables, many of which are being published here for the first time. Though the book is written at an academic level, it focuses very much on practical applications, which reflects the authors' extensive involvement with both laboratory research and industrial practices.
Presenting a comprehensive treatment of grinding theory and its practical utilization, this edition focuses on grinding as a machining process using bonded abrasive grinding wheels as the cutting medium. It provides a description of abrasives and bonded abrasive cutting tools.
Written by an expert with over 40 years of experience in research and teaching machining and related topics, this new edition textbook presents the principles and theories of material removal and applications for conventional, nonconventional and hybrid machining processes. The new edition is ideal for undergraduate students in production, materials, industrial, mechatronics, marine, mechanical, and manufacturing engineering programs, and also useful for graduate programs related to higher-level machining topics, as well as professional engineers and technicians. All chapters are updated, with additional chapters covering new topics of composite machining, vibration assisted machining and mass finishing operations. Features Presents a wide spectrum of metal cutting, abrasive machining, nonconventional and hybrid machining processes Analyzes the chip formation in machining by cutting and abrasion processes as well as the material removal mechanisms in the nonconventional and the hybrid processes Explains the role of each process variables on its behavior and technological characteristics in terms of material removal, product accuracy and surface quality Portrays the theoretical and empirical formula for removal rates and surface finish in different processes as well as very useful technical data that help in solving and analysis of day-to-day shop floor problems that face manufacturing engineers Clarifies the machinability concept and introduces the general guidelines for machining process selection
This book presents the advances in abrasive based machining and finishing in broad sense. Specifically, the book covers the novel machining and finishing strategies implemented in various advanced machining processes for improving machining accuracy and overall quality of the product. This book presents the capability of advanced machining processes using abrasive grain. It also covers ways for enhancing the production rate as well as quality. It fulfills the gap between the production of any complicated components and successful machining with abrasive particles.
This book draws upon the science of tribology to understand, predict and improve abrasive machining processes. Pulling together information on how abrasives work, the authors, who are renowned experts in abrasive technology, demonstrate how tribology can be applied as a tool to improve abrasive machining processes. Each of the main elements of the abrasive machining system are looked at, and the tribological factors that control the efficiency and quality of the processes are described. Since grinding is by far the most commonly employed abrasive machining process, it is dealt with in particular detail. Solutions are posed to many of the most commonly experienced industrial problems, such as poor accuracy, poor surface quality, rapid wheel wear, vibrations, work-piece burn and high process costs. This practical approach makes this book an essential tool for practicing engineers. Uses the science of tribology to improve understanding and of abrasive machining processes in order to increase performance, productivity and surface quality of final products A comprehensive reference on how abrasives work, covering kinematics, heat transfer, thermal stresses, molecular dynamics, fluids and the tribology of lubricants Authoritative and ground-breaking in its first edition, the 2nd edition includes 30% new and updated material, including new topics such as CMP (Chemical Mechanical Polishing) and precision machining for micro-and nano-scale applications
This new edition draws upon the fundamentals of abrasive machining processes and the science of tribology to understand, predict, and improve abrasive machining processes. Each of the main elements of the abrasive machining system is looked at alongside the tribological factors that control the efficiency and quality of the processes described. The new edition has been updated to include a variety of industrial applications. Grinding and conditioning of grinding tools are dealt with in particular detail, and solutions are proposed for many of the most commonly experienced industrial problems, such as poor accuracy, poor surface quality, rapid tool wear, vibrations, workpiece burn, and high process costs. The entire book has been rewritten and restructured, with ten completely new chapters. Other new features include: - Extensive explanations of the main abrasive machining processes such as grinding (including reciprocating and creep-feed grinding, high-speed high-efficiency deep grinding, external and internal cylindrical grinding, and centerless grinding), honing, superfinishing, lapping, polishing, and finishing - Discussions of the new classes of abrasives, abrasive tools, and bonding materials - New case studies and troubleshooting on the most common grinding practices - New coverage on grinding tool conditioning, mechanical dressing, and nonmechanical dressing processes - Detailed explanations of the effects of process input parameters (such as cutting parameters, workpiece material and geometry, and abrasive tools) on process characteristics, workpiece quality, tool wear, and process parameters (such as cutting forces and temperature as well as achievable material removal rate) - Updated topics regarding process fluids for abrasive machining and fluid delivery
The future of manufacturing companies depends largely on their ability to adapt to swiftly changing global conditions. These are exemplified by international com- tition, rapidly growing intercommunication and the increased significance of en- ronmental issues [KLOC98a, ENGE02]. Precision machining with geometrically undefined cutting edges represents a key production engineering technology with high efficiency, security and machining quality. DIN norm 8589 subsumes within the group “machining with geometrically - defined cutting edges” the following material removal manufacturing processes: grinding, honing, lapping, free abrasive grinding and abrasive blast cutting. - chining is carried out in these production methods by means of more or less - regularly formed grains composed of hard substances brought into contact with the material. Of all methods understood as machining with geometrically undefined cutting edges, only grinding, honing and lapping can, strictly speaking, be considered p- cision machining. Free abrasive grinding and abrasive blast cutting, also treated in this book, represent a special group, as they generally cannot bring about geom- rical change in the material.