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Machining for dummies
\"This hands-on guide begins with basic topics like tools, work holding, and ancillary equipment, then goes into drilling, milling, turning, and other necessary metalworking processes. You'll also learn about robotics and new developments in machining technology that are driving the future of manufacturing and the machining market\"--Amazon.com.
Book
Machining of biocompatible materials: a review
The need for more effective and efficient manufacturing processes to transform the biocompatible materials into high standard artificial human body components (implants) is rapidly growing. Machining of biocompatible materials as one of the key processes in manufacturing of implants need to be improved due to the significant effects of machined surface quality to the compatibility and osseointegration with human organs such as tissues, bones, and environment of the human body. The challenges of machining biocompatible materials due to their applications as bio-implants in the human body and the nature of materials properties and microstructures have been explored and solved by various researchers. This article reviews the trends and developments of the machining of biocompatible materials. A range of possible machining technologies and strategies on various biocompatible materials using conventional (milling, turning and drilling) and non-conventional or advanced (abrasive water jet machining (AWJM), ultrasonic machining (USM), ion beam machining (IBM), laser beam machining (LBM), electrical discharge machining (EDM), and electron beam machining (EBM)) are presented and discussed. This review also examines the emerging new technologies such as additives manufacturing and hybrid processes as potential solutions and future research trends in order to fulfill the high standard requirements for a wider range of applications of the biomaterials.
Journal Article
Precision machining technology
\"Introduces students, both at the secondary and postsecondary levels, to the exciting world of precision machining technology as it is practiced in the 21st century.\"
Book
A review on machining and optimization of particle-reinforced metal matrix composites
This paper offers a comprehensive literature review of the conventional machining processes along with optimization methods used in metal matrix composites (MMCs), such as turning, milling, drilling, and grinding machining processes. The tool wear mechanism and machinability of MMCs along with surface quality are discussed in the number of different manufacturing processes and examined thoroughly. Additionally, the manufacturing of MMC products through nonconventional machining processes such as electrical discharge machining (EDM), wire electrical discharge machining (WEDM), laser machining, electrochemical machining, ultra- sonic machining (USM), and high-speed machining are investigated and considered, in connection with MMC processing are discussed, as alternatives to the aforementioned processes. Moreover, this review focuses on the modeling of the machining process, finite element modeling, and simulation and optimization of soft computing methods in MMCs. The study will emphasize on the most generally used methods, namely, response surface methodology, artificial neural network, Taguchi method, and fuzzy logic as soft computing optimization methods. Finally, the comprehensive open issues and conclusions have drawn on the machining and optimization of particle-reinforced MMCs.
Journal Article
Optimization of Tool Wear and Cutting Parameters in SCCOsub.2-MQL Ultrasonic Vibration Milling of SiCp/Al Composites
Silicon carbide particle-reinforced aluminum matrix (SiCp/Al) composites are significant lightweight metal matrix composites extensively utilized in precision instruments and aerospace sectors. Nevertheless, the inclusion of rigid SiC particles exacerbates tool wear in mechanical machining, resulting in a decline in the quality of surface finishes. This work undertakes a comprehensive investigation into the problem of tool wear in SiCp/Al composite materials throughout the machining process. Initially, a comprehensive investigation was conducted to analyze the effects of cutting velocity vc, feed per tooth fz, milling depth ap, and milling width ae on tool wear during high-speed milling under SCCO[sub.2]-MQL (Supercritical Carbon Dioxide Minimum Quantity Lubrication) ultrasonic vibration conditions. The results show that under the condition of SCCO[sub.2]-MQL ultrasonic vibration, proper control of milling parameters can significantly reduce tool wear, extend tool service life, improve machining quality, and effectively reduce blade breakage and spalling damage to the tool, reduce abrasive wear and adhesive wear, and thus significantly improve the durability of the tool. Furthermore, a prediction model for tool wear was developed by employing the orthogonal test method and multiple linear regression. The model’s relevance and accuracy were confirmed using F-tests and t-tests. The results show that the model can effectively predict tool wear, among which cutting velocity vc and feed rate fz are the key parameters affecting the prediction accuracy. Finally, a genetic algorithm was used to optimize the milling parameters, and the optimal parameter combination (vc = 60.00 m/min, fz = 0.08 mm/z, ap = 0.20 mm) was determined, and the optimized milling parameters were tested. Empirical findings suggest that the careful selection of milling parameters can significantly mitigate tool wear, extend the lifespan of the tool, and enhance the quality of the surface. This work serves as a significant point of reference for the processing of SiCp/Al composite materials.
Journal Article
High-speed image based identification of the friction coefficient in metal cutting/Reibkoeffizientenermittlung in der Zerspanung auf Basis von Hochgeschwindigkeitsaufnahmen
The friction at the cutting wedge has a significant influence on tool wear. Due to the strong local variance of temperatures and stresses at the cutting wedge, the friction conditions differ significantly locally. In this work, a method is presented with which normal stresses, tangential stresses and local friction coefficients at the cutting wedge can be determined based on experimental investigations. For this purpose, high-speed recordings and force measurements are conducted on a planing test rig. In addition to dry cutting processes, investigations are carried out on the test rig using emulsion and oil as metal working fluid. The results show a reduction of the coefficients of friction when oil is used as metal working fluid. However, when emulsion is used as metal working fluid, the coefficient of friction changes only slightly compared to dry machining. This can be attributed to low film-forming ability of the emulsion. Keywords Machining, load stresses, cooling lubricant, tribometry, coefficient of friction, emulsion Die Reibung am Schneidkeil beeinflusst massgeblich das Verschleissverhalten in der Zerspanung. Aufgrund der starken ortlichen Varianz von Temperaturen und Spannungen am Schneidkeil unterscheiden sich die Reibverhaltnisse lokal signifikant. In dieser Arbeit wird eine Methode vorgestellt, mit der Normalspannungen, Tangentialspannungen und lokale Reibkoeffizienten am Schneidkeil auf Basis experimenteller Untersuchungen bestimmt werden konnen. Zu diesem Zweck werden Hochgeschwindigkeitsaufnahmen und Kraftmessungen an einem Hobelprufstand erstellt. Neben trockenen Zerspanprozessen werden an dem Prufstand Untersuchungen mit Emulsion und Ol als Kuhlschmierstoff durchgefuhrt. Die Ergebnisse zeigen einen Abfall der Reibkoeffizienten beim Einsatz von Ol als Kuhlschmierstoff. Beim Einsatz von Emulsion als Kuhlschmierstoff verandert sich der Reibkoeffizient gegenuber der trockenen Zerspanung jedoch nur geringfugig. Dies kann auf geringe Fahigkeit der Emulsion zur Filmbildung zuruckgefuhrt werden. Schlusselworter Zerspanung, Lastspannungen, Kuhlschmierstoff, Tribometrie, Reibkoeffizient, Emulsion
Journal Article
Process characteristics of electrochemical discharge machining and hybrid methods: a review
Electrochemical discharge machining (ECDM) combines the process characteristics of both electric discharge machining (EDM) and electrochemical machining (ECM). ECDM combines the advantages of both processes to achieve high precision and high surface-quality machining. It has a broad application prospect. This paper briefly introduces the development history of ECDM. The machining mechanism of ECDM is explained. The applications of ECDM machining features are listed, including drilling, milling, turning, cutting, and hybrid machining methods, for process performance enhancement. A comprehensive analysis of the process parameters of ECDM and their impact on process performance is presented. The paper surveys the extensive ECDM research and concludes with a discussion of the future direction of ECDM.
Journal Article
A comprehensive review on metallic implant biomaterials and their subtractive manufacturing
There is a tremendous increase in the demand for converting biomaterials into high-quality industrially manufactured human body parts, also known as medical implants. Drug delivery systems, bone plates, screws, cranial, and dental devices are the popular examples of these implants - the potential alternatives for human life survival. However, the processing techniques of an engineered implant largely determine its preciseness, surface characteristics, and interactive ability with the adjacent tissue(s) in a particular biological environment. Moreover, the high cost-effective manufacturing of an implant under tight tolerances remains a challenge. In this regard, several subtractive or additive manufacturing techniques are employed to manufacture patient-specific implants, depending primarily on the required biocompatibility, bioactivity, surface integrity, and fatigue strength. The present paper reviews numerous non-degradable and degradable metallic implant biomaterials such as stainless steel (SS), titanium (Ti)-based, cobalt (Co)-based, nickel-titanium (NiTi), and magnesium (Mg)-based alloys, followed by their processing via traditional turning, drilling, and milling including the high-speed multi-axis CNC machining, and non-traditional abrasive water jet machining (AWJM), laser beam machining (LBM), ultrasonic machining (USM), and electric discharge machining (EDM) types of subtractive manufacturing techniques. However, the review further funnels down its primary focus on Mg, NiTi, and Ti-based alloys on the basis of the increasing trend of their implant applications in the last decade due to some of their outstanding properties. In the recent years, the incorporation of cryogenic coolant-assisted traditional subtraction of biomaterials has gained researchers’ attention due to its sustainability, environment-friendly nature, performance, and superior biocompatible and functional outcomes fitting for medical applications. However, some of the latest studies reported that the medical implant manufacturing requirements could be more remarkably met using the non-traditional subtractive manufacturing approaches. Altogether, cryogenic machining among the traditional routes and EDM among the non-traditional means along with their variants, were identified as some of the most effective subtractive manufacturing techniques for achieving the dimensionally accurate and biocompatible metallic medical implants with significantly modified surfaces.
Journal Article
Analysis of Oversize of Engine Compressor Disk
In order to solve the problem of the extreme axial position of the engine compressor during the process of machining, three kinds of calculation States were selected according to the extreme difference, and the influence of the excess on the stress and deformation of the compressor was determined.
Journal Article