Metal Machining: Theory and Applications

K. Maekawa, T. Obikawa, Y. Yamane, T.H.C. Childs9780340691595, 0-340-69159-X

Metal machining is one of the most widespread and economically important engineering industry manufacturing processes. Although it is an old and established process, changes and improvements occur constantly in response to new materials and new needs for, and pressures on, productivity. This book explains the mechanical, thermal and materials principles of the process and shows how these principles determine industrial application conditions. Its coverage ranges from classical analysis and methods of production optimization to the uses of finite element and artificial intelligence methods for predicting machining performance.

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Table of contents :
Contents……Page 3
Preface……Page 7
1 Introduction……Page 9
1.1 Machine tool technology……Page 11
1.2 Manufacturing systems……Page 23
1.3 Materials technology……Page 27
1.4 Economic optimization of machining……Page 32
1.5 A forward look……Page 40
2.1 Historical introduction……Page 43
2.2 Chip formation mechanics……Page 45
2.3 Thermal modelling……Page 65
2.4 Friction, lubrication and wear……Page 73
2.5 Summary……Page 87
3 Work and tool materials……Page 89
3.1 Work material characteristics in machining……Page 90
3.2 Tool materials……Page 105
4.1 Tool damage and its classification……Page 126
4.2 Tool life……Page 138
4.3 Summary……Page 142
5.1 Microscopic examination methods……Page 144
5.2 Forces in machining……Page 147
5.3 Temperatures in machining……Page 155
5.4 Acoustic emission……Page 163
6.2 Slip-line field modelling……Page 167
6.3 Introducing variable flow stress behaviour……Page 175
6.4 Non-orthogonal (three-dimensional) machining……Page 185
7.1 Finite element background……Page 207
7.2 Historical developments……Page 212
7.3 The Iterative Convergence Method (ICM)……Page 220
7.4 Material flow stress modelling for finite element analyses……Page 228
8.1 Simulation of BUE formation……Page 234
8.2 Simulation of unsteady chip formation……Page 242
8.3 Machinability analysis of free cutting steels……Page 248
8.4 Cutting edge design……Page 259
8.5 Summary……Page 270
9.1 Introduction……Page 273
9.2 Process models……Page 275
9.3 Optimization of machining conditions and expert system applications……Page 291
9.4 Monitoring and improvement of cutting states……Page 313
9.5 Model-based systems for simulation and control of machining processes……Page 325
Appendix 1 Metals’ plasticity, and its finite element formulation……Page 336
A1.1 Yielding and flow under triaxial stresses: initial concepts……Page 337
A1.2 The special case of perfectly plastic material in plane strain……Page 340
A1.3 Yielding and flow in a triaxial stress state: advanced analysis……Page 348
A1.4 Constitutive equations for numerical modelling……Page 351
A1.5 Finite element formulations……Page 356
A2.1 The differential equation for heat flow in a solid……Page 359
A2.2 Selected problems, with no convection……Page 361
A2.3 Selected problems, with convection……Page 363
A2.4 Numerical (finite element) methods……Page 365
A3.1 Introduction……Page 371
A3.2 The normal contact of a single asperity on an elastic foundation……Page 373
A3.3 The normal contact of arrays of asperities on an elastic foundation……Page 376
A3.4 Asperities with traction, on an elastic foundation……Page 377
A3.5 Bulk yielding……Page 379
A3.6 Friction coefficients greater than unity……Page 381
A4.1 Work material: room temperature, low strain rate, strain hardening behaviours……Page 383
A4.2 Work material: thermal properties……Page 384
A4.3 Work material: strain hardening behaviours at high strain rates and temperatures……Page 387
A5.1 Tool yielding……Page 391
A5.2 Tool fracture……Page 393
A6.1 High speed steels……Page 395
A6.2 Cemented carbides and cermets……Page 396
A6.3 Ceramics and superhard materials……Page 401
A7.1 Fuzzy sets……Page 404
A7.2 Fuzzy operations……Page 406
Index……Page 409