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

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.

Today’s stringent design requirements and difficult-to-machine materials such as tough super alloys, ceramics, and composites, have made traditional machining processes costly and obsolete. As a result, manufacturers and machine design engineers are turning to advance machining processes. These machining processes utilizes electrical, chemical, and optimal sources of energy to bind, form and cut materials. El-Hofy rigorously explains how each of these advanced machining process work, their machining system components, process variables and industrial applications, making this book the perfect guide for anyone designing, researching or converting to a more advance machining process.

Machining of Metal Matrix Composites provides the fundamentals and recent advances in the study of machining of metal matrix composites (MMCs). Each chapter is written by an international expert in this important field of research. Machining of Metal Matrix Composites gives the reader information on machining of MMCs with a special emphasis on aluminium matrix composites. Chapter 1 provides the mechanics and modelling of chip formation for traditional machining processes. Chapter 2 is dedicated to surface integrity when machining MMCs. Chapter 3 describes the machinability aspects of MMCs. Chapter 4 contains information on traditional machining processes and Chapter 5 is dedicated to the grinding of MMCs. Chapter 6 describes the dry cutting of MMCs with SiC particulate reinforcement. Finally, Chapter 7 is dedicated to computational methods and optimization in the machining of MMCs. Machining of Metal Matrix Composites can serve as a useful reference for academics, manufacturing and materials researchers, manufacturing and mechanical engineers, and professionals involved with MMC applications. It can also be used to teach modern manufacturing engineering or as a textbook for advanced undergraduate and postgraduate engineering courses in machining, manufacturing or materials.

Metals are still the most widely used structural materials in the manufacture of products and structures. Their properties are extremely dependent on the processes they undergo to form the final product. Successful manufacturing therefore depends on a detailed knowledge of the processing of the materials involved. This highly illustrated book provides that knowledge. Metal processing is a technical subject requiring a quantitative approach. This book illustrates this approach with real case studies derived from industry. Real industrial case studies Quantitative approach Challenging student problems

Advanced Machining Processes of Metallic Materials updates our knowledge on the metal cutting processes in relation to theory and industrial practice. In particular, many topics reflect recent developments, e.g. modern tool materials, computational machining, computer simulation of various process phenomena, chip control, monitoring of the cutting state, progressive and hybrid machining operations, and generation and modelling of surface integrity. This book addresses the present state and future development of machining technologies. It provides a comprehensive description of metal cutting theory, experimental and modelling techniques along with basic machining processes and their effective use in a wide range of manufacturing applications. Topics covered include fundamental physical phenomena and methods for their evaluation, available technology of machining processes for specific classes of materials and surface integrity. The book also provides strategies for optimalization techniques and assessment of machinability. Moreover, it describes topics not currently covered in other sources, such as high performance and multitasking (complete) machining with a high potential for increasing productivity, and virtual and e-machining. The research covered here has contributed to a more generalized vision of machining technology, including not only traditional manufacturing tasks but also new potential (emerging) applications such as micro- and nanotechnology. Many practical examples of modern machining technology Applicable for various technical, engineering and scientific levels Collects together 20 years of research in the field and related technical information

A Complete Reference Covering the Latest Technology in Metal Cutting Tools, Processes, and Equipment Metal Cutting Theory and Practice, Third Edition shapes the future of material removal in new and lasting ways. Centered on metallic work materials and traditional chip-forming cutting methods, the book provides a physical understanding of conventional and high-speed machining processes applied to metallic work pieces, and serves as a basis for effective process design and troubleshooting. This latest edition of a well-known reference highlights recent developments, covers the latest research results, and reflects current areas of emphasis in industrial practice. Based on the authors’ extensive automotive production experience, it covers several structural changes, and includes an extensive review of computer aided engineering (CAE) methods for process analysis and design. Providing updated material throughout, it offers insight and understanding to engineers looking to design, operate, troubleshoot, and improve high quality, cost effective metal cutting operations. The book contains extensive up-to-date references to both scientific and trade literature, and provides a description of error mapping and compensation strategies for CNC machines based on recently issued international standards, and includes chapters on cutting fluids and gear machining. The authors also offer updated information on tooling grades and practices for machining compacted graphite iron, nickel alloys, and other hard-to-machine materials, as well as a full description of minimum quantity lubrication systems, tooling, and processing practices. In addition, updated topics include machine tool types and structures, cutting tool materials and coatings, cutting mechanics and temperatures, process simulation and analysis, and tool wear from both chemical and mechanical viewpoints. Comprised of 17 chapters, this detailed study: Describes the common machining operations used to produce specific shapes or surface characteristics Contains conventional and advanced cutting tool technologies Explains the properties and characteristics of tools which influence tool design or selection Clarifies the physical mechanisms which lead to tool failure and identifies general strategies for reducing failure rates and increasing tool life Includes common machinability criteria, tests, and indices Breaks down the economics of machining operations Offers an overview of the engineering aspects of MQL machining Summarizes gear machining and finishing methods for common gear types, and more Metal Cutting Theory and Practice, Third Edition emphasizes the physical understanding and analysis for robust process design, troubleshooting, and improvement, and aids manufacturing engineering professionals, and engineering students in manufacturing engineering and machining processes programs.