Metal cutting is a widely used method of producing manufactured products. The technology of metal cutting has advanced considerably along with new materials, computers, and sensors. This new edition treats the scientific principles of metal cutting and their practical application to manufacturing problems. It begins with metal cutting mechanics, principles of vibration, and experimental modal analysis applied to solving shop floor problems. Notable is the in-depth coverage of chatter vibrations, a problem experienced daily by manufacturing engineers. The essential topics of programming, design, and automation of CNC (computer numerical control) machine tools, NC (numerical control) programming, and CAD/CAM technology are discussed. The text also covers the selection of drive actuators, feedback sensors, modeling and control of feed drives, the design of real time trajectory generation and interpolation algorithms, and CNC-oriented error analysis in detail. Each chapter includes examples drawn from industry, design projects, and homework problems. This book is ideal for advanced undergraduate and graduate students, as well as practicing engineers.

Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design

Achieving sustainability in manufacturing requires a holistic view spanning not just the product, and the manufacturing processes involved in its fabrication, but also the entire supply chain, including the manufacturing systems across multiple product life-cycles. This requires improved models, metrics for sustainability evaluation, and optimization techniques at the product, process, and system levels. This paper presents an overview of recent trends and new concepts in the development of sustainable products, processes and systems. In particular, recent trends in developing improved sustainability scoring methods for products and processes, and predictive models and optimization techniques for sustainable manufacturing processes, focusing on dry, near-dry and cryogenic machining as examples, are presented.

Sustainable manufacturing: Modeling and optimization challenges at the product, process and system levels

Surface integrity in material removal processes: Recent advances

https://escholarship.org/content/qt7hd8r1ft/qt7hd8r1ft.pdf

Advancing Cutting Technology

Recent advances in modelling of metal machining processes

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Mechanics of Machining: An Analytical Approach to Assessing Machinability

In an attempt to overcome the deficiencies of existing theories of cutting, an experimental technique was developed for observing the cutting process during slow orthogonal cutting of mild steel. An attempt to find consistency between the observations and the ideal theory of plasticity failed. Consequently the theory was extended by including the effect of work- hardening and, in spite of the laborious nature of the analysis, it appeared that consistency had been regained. This led to a novel and physically consistent picture of the cutting process, which was taking place during the tests.

Mechanics of Orthogonal Machining

A numerical method for calculating temperature distributions in machining, from force and shear angle measurements

An approximate machining theory is described in which account is taken of the temperature and strain-rate dependent properties of the work material. A feature of the theory is that the strain rates in the zones of intense plastic deformation in which the chip is formed and along the tool/ chip interface are determined as part of the solution. The theory is applied to make predictions for two plain carbon steels and a range of cutting conditions by using flow stress data obtained from high speed compression tests and excellent agreement is shown, for example, between predicted and experimental cutting forces. The values of tool/chip interface plastic zone thickness predicted by assuming a minimum work criterion are shown to agree well with experimental values, both experiment and theory indicating a marked decrease in thickness with increase in cutting speed. It is also shown how the temperatures and strain rates in this zone can be used to determine the conditions that cause a built-up edge to be formed on the cutting tool and good agreement is again shown with experimental results.

P. L. B. Oxley

Papers

Mechanics of Machining: An Analytical Approach to Assessing Machinability

Mechanics of Orthogonal Machining

A numerical method for calculating temperature distributions in machining, from force and shear angle measurements

A machining theory for predicting chip geometry, cutting forces etc. from work material properties and cutting conditions

Prediction of Archard's wear coefficient for metallic sliding friction assuming a low cycle fatigue wear mechanism