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Metal cutting is the process of removing unwanted material in the form of chips from a block of metal using cutting tools. Metal cutting is performed on lathe machine, milling machine, drilling machine, shaper, planer and slotter. Grinding is the commonly used finishing process. Metal forming includes a large number of manufacturing processes in which plastic deformation property is used to change the shape and size of metal workpieces. During the process, for deformation purpose, a tool is used which is called as die. It applies stresses to the material to exceed the yield strength of the metal. Due to this the metal deforms into the shape of the die. Generally, the stresses applied to deform the metal plastically are compressive. Sheet metal working is generally associated with press machines and press working. Press working is a chipless manufacturing process by which various components are produced form sheet metal.
Metal Cutting Theory and Practice by David A. Stephenson,John S. Agapiou Pdf
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.
Following the long tradition of the Schuler Company, the Metal For ming Handbook presents the scientific fundamentals of metal forming technology in a way which is both compact and easily understood. Thus, this book makes the theory and practice of this field accessible to teaching and practical implementation. The first Schuler "Metal Forming Handbook" was published in 1930. The last edition of 1966, already revised four times, was translated into a number of languages, and met with resounding approval around the globe. Over the last 30 years, the field of forming technology has been rad ically changed by a number of innovations. New forming techniques and extended product design possibilities have been developed and introduced. This Metal Forming Handbook has been fundamentally revised to take account of these technological changes. It is both a text book and a reference work whose initial chapters are concerned to pro vide a survey of the fundamental processes of forming technology and press design. The book then goes on to provide an in-depth study of the major fields of sheet metal forming, cutting, hydroforming and solid forming. A large number of relevant calculations offers state of the art solutions in the field of metal forming technology. In presenting tech nical explanations, particular emphasis was placed on easily under standable graphic visualization. All illustrations and diagrams were compiled using a standardized system of functionally oriented color codes with a view to aiding the reader's understanding.
As the only comprehensive text focusing on metal shaping processes, which are still the most widely used processes in the manufacture of products and structures, Metal Shaping Processes carefully presents the fundamentals of metal shaping processes with their relevant applications. The treatment of the subject matter is adequately descriptive for those unfamiliar with the various processes and yet is sufficiently analytical for an introductory academic course in manufacturing. The text, as well as the numerous formulas and illustrations in each chapter, clearly show that shaping processes, as a part of manufacturing engineering, are a complex and interdisciplinary subject. The topics are organized and presented in such a manner that they motivate and challenge students to present technically and economically viable solutions to a wide variety of questions and problems, including product design. It is the perfect textbook for students in mechanical, industrial, and manufacturing engineering programs at both the Associate Degree and Bachelor Degree programs, as well a valuable reference for manufacturing engineers (those who design, execute and maintain the equipment and tools); process engineers (those who plan and engineer the manufacturing steps, equipment, and tooling needed in production); manufacturing managers and supervisors; product design engineers; and maintenance and reliability managers and technicians. Each chapter begins with a brief highlighted outline of the topics to be described. Carefully presents the fundamentals of the particular metal-shaping process with its relevant applications within each chapter, so that the student and teacher can clearly assess the capabilities, limitation, and potentials of the process and its competitive aspects. Features sections on product design considerations, which present guidelines on design for manufacturing in many of the chapters. Offers practical, understandable explanations, even for complex processes. Includes text entries that are coded as in an outline, with these numerical designations carried over the 320 related illustrations for easy cross-referencing. Provides a dual (ISO and USA) unit system. Contains end-of-chapter Review Questions. Includes a chapter on sheet metalworking covering cutting processes; bending process; tubes and pipe bending; deep drawing processes; other sheet metal forming process (stretch forming, spinning, rubber forming, and superplatic forming and diffusion bonding). Provides a useful die classification with 15 illustrations and description; presses for sheet metalworking; and high energy-rate forming processes. A chapter on nontraditional manufacturing process discusses such important processes as mechanical energy processes (ultrasonic machining, water jet cutting); electrochemical machining processes (electrochemical machining, electrochemical grinding); thermal energy processes (electric discharge processes, laser beam machining, electron beam machining); and chemical processes (chemical milling). Part I: Casting and Molding Fundamentals of Metal Casting Metal-Casting Processes Metal Casting: Design and Materials Part II: Particulate Processing for Metals Powder Metallurgy Part III: Deformation Processes Fundamentals of Metal FormingRolling of Metals Forging. Extrusion and Drawing of Metals Sheet Metalworking Part IV: Metal Removal Processes Fundamentals of Metal Machining Machining Processes Abrasive Machining Processes Nontraditional Machining Processes Appendix Index
Expanded and revised to include changes and additions to metal cutting theory. Covers developments in tool materials and industrial practice over the last seven years. Describes the stresses and temperatures acting on cutting tools and explains their influence on performance. Discusses tool wear which determines cutting efficiency. Details machinability and control of tool material structure and composition.
Metal machining is the most widespread metal-shaping process in the mechanical manufacturing industry. World-wide investment in metal machining tools increases year on year - and the wealth of nations can be judged by it. This text - the most up-to-date in the field - provides in-depth discussion of the theory and application of metal machining at an advanced level. It begins with an overview of the development of metal machining and its role in the current industrial environment and continues with a discussion of the theory and practice of machining. The underlying mechanics are analysed in detail and there are extensive chapters examining applications through a discussion of simulation and process control. "metal Machining: Theory and Applications" is essential reading for senior undergraduates and postgraduates specialising in cutting technology. It is also an invaluable reference tool for professional engineers. Professors Childs, Maekawa, Obikawa and Yamane are four of the leading authorities on metal machining and have worked together for many years.
This sourcebook presents the most important metal-working and shearing processes - and their related machines and tooling - in a concise form supplemented by ample illustrations, tables and flow charts. Practical examples show how to calculate forces and strain energy of the processes and the specific parameters of the machines, and exercises help readers improve understanding. Because much production today is automated using modern Computer Numerical Control engineering, the book covers automated flexible metal forming and handling systems. Carefully translated from the eighth revised German-language edition, Metal Forming Practise offers a valuable reference tool for students, engineers and technicians.
Fundamentals of Metal Cutting and Machine Tools by B. L. Juneja Pdf
The Book Is Intended To Serve As A Textbook For The Final And Pre-Final Year B.Tech. Students Of Mechanical, Production, Aeronautical And Textile Engineering Disciplines. It Can Be Used Either For A One Or A Two Semester Course. The Book Covers The Main Areas Of Interest In Metal Machining Technology Namely Machining Processes, Machine Tools, Metal Cutting Theory And Cutting Tools. Modern Developments Such As Numerical Control, Computer-Aided Manufacture And Non-Conventional Processes Have Also Been Treated. Separate Chapters Have Been Devoted To The Important Topics Of Machine Tool Vibration, Surface Integrity And Machining Economics. Data On Recommended Cutting Speeds, Feeds And Tool Geometry For Various Operations Has Been Incorporated For Reference By The Practising Engineer.Salient Features Of Second Edition * Two New Chapters Have Been Added On Nc And Cnc Machines And Part Programming. * All Chapters Have Been Thoroughly Revised And Updated With New Information. * More Solved Examples Have Been Added. * New Material On Tool Technology. * Improved Quality Of Figures And More Photographs.
Machining Difficult-to-Cut Materials by Hossam A. Kishawy,Ali Hosseini Pdf
This book focus on the challenges faced by cutting materials with superior mechanical and chemical characteristics, such as hardened steels, titanium alloys, super alloys, ceramics and metal matrix composites. Aspects such as costs and appropriate machining strategy are mentioned. The authors present the characteristics of the materials difficult to cut and comment on appropriate cutting tools for their machining. This book also serves as a reference tool for manufacturers working in industry.
Handbook of Metalforming Processes by Henry Ericsson Theis Pdf
Reflecting hands-on experience of materials, equipment, tooling and processes used in the industry, this work provides up-to-date information on flat-rolled sheet metal products. It addresses the processing and forming of light-to-medium-gauge flat-rolled sheet metal, illustrating the versatility and myriad uses of this material.
Friction & Flow Stress in Forming & Cutting by Philippe Boisse,Taylan Altan,Kees van Luttervelt Pdf
In recent years, significant developments have taken place in the application of computational mechanics to cutting and forming operations. The process itself can be affected by very high flow stresses that occur under the extreme conditions created by such operations. . Material behavior, friction, wear and related phenomena can be studied both in actual manufacturing operations and in test set-ups, and mathematical relations thus derived, but doubts have recently arisen about the relationship of such extrapolations to actual industrial operations. The contributors discuss the state of the art and new developments with emphasis on friction and flow stress in actual industrial processes, the modeling of friction and flow stress, the testing under simulated conditions in order to model friction and flow stress in actual industrial processes, the acquisition of detailed information related to fundamental aspects of recent developments like the use of coated tools, high speed machining, unusual workmaterials,,and microprocessing.
Micro Metal Forming, i. e. forming of parts and features with dimensions below 1 mm, is a young area of research in the wide field of metal forming technologies, expanding the limits for applying metal forming towards micro technology. The essential challenges arise from the reduced geometrical size and the increased lot size. In order to enable potential users to apply micro metal forming in production, information about the following topics are given: tribological behavior: friction between tool and work piece as well as tool wear mechanical behavior: strength and formability of the work piece material, durability of the work pieces size effects: basic description of effects occurring due to the fact, that the quantitative relation between different features changes with decreasing size process windows and limits for forming processes tool making methods numerical modeling of processes and process chains quality assurance and metrology All topics are discussed with respect to the questions relevant to micro metal forming. The description comprises information from actual research and the young history of this technology branch to be used by students, scientists and engineers in industry who already have a background in metal forming and like to expand their knowledge towards miniaturization. tribological behavior: friction between tool and work piece as well as tool wear mechanical behavior: strength and formability of the work piece material, durability of the work pieces size effects: basic description of effects occurring due to the fact, that the quantitative relation between different features changes with decreasing size process windows and limits for forming processes tool making methods numerical modeling of processes and process chains quality assurance and metrology All topics are discussed with respect to the questions relevant to micro metal forming. The description comprises information from actual research and the young history of this technology branch to be used by students, scientists and engineers in industry who already have a background in metal forming and like to expand their knowledge towards miniaturization.
