Provides an in-depth understanding of the fundamentals of a wide range of state-of-the-art materials manufacturing processes
Modern manufacturing is at the core of industrial production from base materials to semi-finished goods and final products. Over the last decade, a variety of innovative methods have been developed that allow for manufacturing processes that are more versatile, less energy-consuming, and more environmentally friendly. This book provides readers with everything they need to know about the many manufacturing processes of today.
Presented in three parts, Modern Manufacturing Processes starts by covering advanced manufacturing forming processes such as sheet forming, powder forming, and injection molding. The second part deals with thermal and energy-assisted manufacturing processes, including warm and hot hydrostamping. It also covers high speed forming (electromagnetic, electrohydraulic, and explosive forming). The third part reviews advanced material removal process like advanced grinding, electro-discharge machining, micro milling, and laser machining. It also looks at high speed and hard machining and examines advances in material modeling for manufacturing analysis and simulation.
- Offers a comprehensive overview of advanced materials manufacturing processes
- Provides practice-oriented information to help readers find the right manufacturing methods for the intended applications
- Highly relevant for material scientists and engineers in industry
Modern Manufacturing Processes is an ideal book for practitioners and researchers in materials and mechanical engineering.
Table of Contents
Foreword xvii
List of Contributors xix
Part I Advanced Forming Processes 1
1 Advances in Stamping 3
Ilyas Kacar and Fahrettin Ozturk
1.1 Introduction 3
References 13
2 Hydroforming 15
C Hartl
2.1 Introduction 15
2.2 Fundamentals 16
2.3 Process Development and Design 33
2.4 Hydroforming Systems 37
2.5 Concluding Remarks 39
References 40
3 Incremental Sheet Forming 47
Rogelio Perez‐Santiago, Isabel Bagudanch, and Maria Luisa Garcia‐Romeu
3.1 Incremental Sheet Forming: General Overview 47
3.2 ISF Variants 49
3.3 Process Cycle 51
3.4 Materials 52
3.5 Formability in ISF 52
3.6 ISF Process Parameters 55
3.7 Accuracy 55
3.8 Simulation 57
3.9 Future Trends in ISF 58
3.10 Case Study 59
3.11 Concluding Remarks 59
References 60
4 Powder Forming 65
Rahmi Unal
4.1 Introduction 65
4.2 Reasons for Using PM Route 67
4.3 Powder Production 69
4.4 Consolidation Techniques 73
4.5 Sintering 79
4.6 Powder Injection Molding (PIM) 82
4.7 Summary and Future Work 84
References 85
5 Injection Molding at Multiscales 89
Danyang Zhao, Minjie Wang, and Donggang Yao
5.1 Introduction 89
5.2 Overview of Injection Molding 91
5.3 Injection Molding of Precision Parts 105
5.4 Injection Molding of Thin Wall Parts 109
5.5 Injection Molding of Microstructured Parts 116
5.6 Injection Molding of Microparts 124
5.7 Simulation of Injection Molding 127
5.8 Summary and Outlook 131
References 132
6 Manufacturing Techniques of Bulk Metallic Glasses 137
Mustafa Bakkal, Umut Karaguzel, and Ali T. Kuzu
6.1 Introduction 137
6.2 Mechanical Properties and Usage of Bulk Metallic Glasses 139
6.3 Rapid Quenching Methods 140
6.4 Water‐Quenching Method 141
6.5 Arc Melting Drop/Suction Casting Method 142
6.6 High‐Pressure Die Casting Method 143
6.7 Copper Mold Casting Method 144
6.8 Cap Casting Method 144
6.9 Centrifugal Casting Method 145
6.10 Metal Foaming Method 146
6.11 Concluding Remarks 147
References 147
7 Micromanufacturing 149
Omer N. Cora and Muammer Koc
7.1 Introduction 149
7.2 Classification of Micromanufacturing Processes 150
7.3 Micromanufacturing Processes 154
References 179
Part II Thermal and Energy‐assisted Manufacturing Processes 185
8 Warm Stamping 187
Fahrettin Ozturk , Serkan Toros, and Ilyas Kacar
8.1 What is Stamping? 187
8.2 Benefits and Usage Areas of Warm Stamping 187
8.3 Warm Stamping and Recent Developments 188
8.4 Effects of Temperature on Strain Hardening for Warm Stamping 194
8.5 Interrelation of Temperature and Strain Rate 196
8.6 Effect of Temperature and Deformation on Elasticity Modulus 198
8.7 Effect of Temperature on Springback 201
8.8 Effect of Temperature on Forming Limit Diagrams (FLD) 204
8.9 Analyze Techniques on Formability at Warm Stamping 205
8.10 The Effects of Lubrication 215
8.11 Future Directions 215
References 216
9 Warm Hydroforming 219
Muammer Koc, Omer N. Cora, Huseyin S. Halkacı, and Mevlut Turkoz
9.1 Introduction 219
9.2 Warm Sheet Hydroforming 220
9.3 Warm Hydromechanical Deep Drawing 230
9.4 Warm Tube Hydroforming 231
References 237
10 Hot Stamping 239
Fahrettin Ozturk , Ilyas Kacar, and Muammer Koc
10.1 Introduction 239
10.2 Process Description and Motivation 240
10.3 Why Hot Stamping? 241
10.4 Automotive Parts by Hot Stamping and Potentials 241
10.5 Advantages and Disadvantages 243
10.6 Process Description and Methods 245
10.7 Cooling for Hot Stamping 254
10.8 Process Control 255
10.9 Modeling and Analysis 255
10.10 Design and Optimization in Hot Stamping 256
10.11 FEA in Hot Stamping 257
10.12 Research and Development Trends and Needs 258
References 262
11 High‐Speed Forming (Electromagnetic, Electrohydraulic, and Explosive Forming) 265
Brad Kinsey and Yannis Korkolis
11.1 Introduction 265
11.2 Electromagnetic Forming and Magnetic Pulsed Welding 267
11.3 Electrohydraulic Forming 274
11.4 Explosive Forming 279
11.5 Emerging Technologies 282
11.6 Metrology and Measurements 284
11.7 Material Characterization 286
11.8 Modeling of High‐Speed Forming Processes 288
11.9 Summary and Future Work 291
References 292
Part III Advanced Material Removal Processes 295
12 High‐Speed Machining 297
Elisa Vazquez and Guillem Quintana
12.1 High‐Speed Machining Overview 297
12.2 High‐Speed Machining Processes and Capabilities 298
12.3 Machine Tools for High‐Speed Machining 298
12.4 Tools for High‐Speed Machining 300
12.5 High‐Speed Machining Applications and Future Trends 305
References 306
13 Hard Machining 309
Durul Ulutan and Tuğrul Ozel
13.1 Introduction 309
13.2 Mechanics of Hard Machining 312
13.3 Cutting Tools 313
13.4 Surface Quality and Integrity 316
13.5 Summary and Conclusions 320
References 320
14 Advances in Material Modeling for Manufacturing Analysis and Simulation (Deformation and Cutting Processes) 323
Elisabetta Ceretti, Claudio Giardini, and Antonio Fiorentino
14.1 Introduction on Material Characterization and Modeling 323
14.2 Material Models and Applications 324
14.3 Failure Models 327
14.4 Modeling of Contact, Friction, and Wear 331
References 347
15 Advanced Grinding 351
Taghi Tawakoli and Amir Daneshi
15.1 Introduction 351
15.2 Grinding Wheels 351
15.3 Bond Materials 353
15.4 Grinding Wheel Conditioning 354
15.5 Grinding Force and Energy 363
15.6 Thermal Damages in Grinding 363
15.7 Environmentally Friendly Grinding 364
15.8 High‐efficiency Deep Grinding (HEDG) 367
15.9 Ultrasonic‐Assisted Grinding (UAG) 367
15.10 Ultrasonic‐Assisted Dressing 371
References 373
16 Electro‐Discharge Machining (EDM) 377
Muhammad P. Jahan
16.1 Introduction 377
16.2 Principle of the EDM Process 378
16.3 EDM System Components 379
16.4 Analysis of the Pulses Used in the EDM Process 383
16.5 Brief Overview of the EDM Parameters 384
16.6 EDM Variants: Working Principles and Application Examples 385
16.7 Examples of Research Advances in EDM and Micro‐EDM 393
16.8 Research Focus Toward Micro‐ and Nano‐EDM 402
16.9 Summary 403
References 404
17 MicroMilling Operations 411
Simon S. Park, Martin B.G. Jun, and Gerardo Garcia
17.1 Introduction 411
17.2 Machine Tools for Micromilling 413
17.3 Micromilling Forces 420
17.4 Tool Tip Dynamics 427
17.5 Summary 430
References 431
18 Laser Machining 427
Dani Teixidor, Ines Ferrer, Luis Criales, and Tuğrul Ozel
18.1 Introduction 435
18.2 Laser-Material Interaction 437
18.3 Laser Processing of Materials 438
18.4 Laser‐Processing Parameters 442
18.5 Laser Drilling 445
18.6 Laser Cutting 448
18.7 Laser Milling 450
18.8 Concluding Remarks 452
References 453
19 Laser‐assisted Machining Operations 459
Eneko Ukar, Ivan Tabernero, Silvia Martinez, Aitzol Lamikiz, and Asier Fernandez
19.1 Introduction 459
19.2 Heat‐assisted Processes 460
19.3 Analysis of LAM Processes 470
19.4 Laser‐assisted Applications 474
19.5 Conclusions 477
References 478
20 Selective Laser Sintering 481
Jordi Delgado, Lidia Sereno, Karla Monroy, and Joaquim Ciurana
20.1 General Overview 481
20.2 Mechanisms 483
20.3 Process Parameters 486
20.4 Materials 490
20.5 Capabilities and Limitations 494
References 496
Index 501
