Compensation of thermo-mechanically induced workpiece and tool deformations during dry turning

Dry turning is accompanied by considerable process-induced deformations of the workpiece and the tool. Such deformations decrease the accuracy of machining. In this paper, finite element models are used in order to calculate the deformations of the workpiece and the tool regarding the cutting condition used. The correction of the depth of cut according to the calculated deformations allows for the compensation of the workpiece and tool deformations. The compensation is carried out by a computer-aided-design / computer-aided-manufacturing (CAD-CAM) approach. The results reveal a significant increase of the machining accuracy in dry turning when compensating the workpiece and tool deformations

Cold Micro Metal Forming

This open access book contains the research report of the Collaborative Research Center “Micro Cold Forming” (SFB 747) of the University of Bremen, Germany. The topical research focus lies on new methods and processes for a mastered mass production of micro parts which are smaller than 1mm (by forming in batch size higher than one million). The target audience primarily comprises research experts and practitioners in production engineering, but the book may also be of interest to graduate students alike

Special Issue of the Manufacturing Engineering Society (MES)

This book derives from the Special Issue of the Manufacturing Engineering Society (MES) that was launched as a Special Issue of the journal Materials. The 48 contributions, published in this book, explore the evolution of traditional manufacturing models toward the new requirements of the Manufacturing Industry 4.0 and present cutting-edge advances in the field of Manufacturing Engineering focusing on additive manufacturing and 3D printing, advances and innovations in manufacturing processes, sustainable and green manufacturing, manufacturing systems (machines, equipment and tooling), metrology and quality in manufacturing, Industry 4.0, product lifecycle management (PLM) technologies, and production planning and risks

Welding Processes

Despite the wide availability of literature on welding processes, a need exists to regularly update the engineering community on advancements in joining techniques of similar and dissimilar materials, in their numerical modeling, as well as in their sensing and control. In response to InTech's request to provide undergraduate and graduate students, welding engineers, and researchers with updates on recent achievements in welding, a group of 34 authors and co-authors from 14 countries representing five continents have joined to co-author this book on welding processes, free of charge to the reader. This book is divided into four sections: Laser Welding; Numerical Modeling of Welding Processes; Sensing of Welding Processes; and General Topics in Welding

Drilling of carbon fibre reinforced plastic composites

Following an extensive literature survey focusing on the machinability of carbon fibre reinforced plastics (CFRP), three main phases of experimental work were undertaken to evaluate the drilling of CFRP and associated stack materials. Phase 1 and 2 involved small diameter holes (1.5 mm) in thin CFRP laminates (3 mm thick) while Phase 3 addressed the feasibility of one-shot drilling (6.35 mm diameter holes) in multilayer workpiece stacks comprising titanium, CFRP and aluminium. Machinability was assessed in terms of tool life/wear, force/torque, hole size and geometrical accuracy, workpiece surface integrity and chip morphology

The selected laser melting production and subsequent post-processing of Ti-6Al-4V prosthetic acetabular

&nbsp;Processing and post processing of human prosthetic acetabular cup by using 3D printing. The results showed using 3D printers leads to fabrication customized implants with higher quality.<br /

Technologies of Coatings and Surface Hardening for Tool Industry

The innovative coating and surface hardening technologies developed in recent years allow us to obtain practically any physical–mechanical or crystal–chemical complex properties of the metalworking tool surface layer. Today, the scientific approach to improving the operational characteristics of the tool surface layers produced from traditional tools industrial materials is a highly costly and long-lasting process. Different technological techniques, such as coatings (physical and chemical methods), surface hardening and alloying (chemical-thermal treatment, implantation), a combination of the listed methods, and other solutions are used for this. This edition aims to provide a review of the current state of the research and developments in the field of coatings and surface hardening technologies for cutting and die tools that can ensure a substantial increase of the work resource and reliability of the tool, an increase in productivity of machining, accuracy, and quality of the machined products, reduction in the material capacity of the production, and other important manufacturing factors. In doing so, the main emphasis should be on the results of the engineering works that have had a prosperous approbation in a laboratory or real manufacturing conditions

Optimizing the surface integrity of machined Ti-6A-4V using advanced carbide inserts and minimum quantity lubrication

A thesis submitted to the Faculty of Engineering and the Built Environment, University of the Witwatersrand, Johannesburg, in fulfilment of the requirements for the degree of Masters of Science in Engineering, 2016This research is focused on optimizing the surface integrity of Ti-6Al-4V using advanced carbide inserts and minimum quantity lubrication (MQL). Experiments were designed to machine twenty Ti-6Al-4V blocks under dry and MQL lubricating conditions using innovative cemented carbide inserts produced by Liquid Phase Sintering (LPS) and Spark Plasma Sintering (SPS). The cutting speed, feed rate, and depth of cut, were considered as machining parameters, while the cutting force, temperature, tool wear, surface roughness and residual stress were considered as performance characteristics. The results obtained for surface roughness and residual stress measurements were used to analyze the surface integrity of the machined Ti-6Al-4V samples. The influence of sintering techniques and milling parameters on performance characteristics and surface integrity were investigated from experimental results obtained. Discrepancy in behavioral trends with respect to lubricating conditions was also investigated. The analyses of milling results showed that cutting speed played a major role in the optimization of surface integrity of the Ti-6Al-4V work pieces followed by the depth of cut. The results also showed that the LPS inserts performed better than the SPS inserts due to their better mechanical properties (higher fracture toughness (KIC) and transverse rupture strength). The application of MQL was also observed to significantly reduce milling temperatures resulting in better surface integrity. However, an optimized surface integrity of the Ti-6Al-4V samples was achieved during MQL milling with the 10Co-L insert at a low finishing speed of 75m/minute and a reduced depth of cut of 0.5mm