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Manufacturing Processes for Engineering Materials
01 Jan 1984-
TL;DR: In this paper, the authors present the fundamental properties of materials and their properties, including surfaces, tribology, dimensional characteristics, inspection, and product quality assurance, and manufacturing properties of metals.
Abstract: 1 Introduction 2 Fundamentals of the mechanical behavior of materials 3 Structure and manufacturing properties of metals 4 Surfaces, tribology, dimensional characteristics, inspection, and product Quality assurance 5 Metal-casting processes and equipment heat treatment 6 Bulk deformation processes 7 Sheet-metal forming processes 8 Material-removal pocesses: cutting 9 Material-removal processes: abrasive, chemical, electrical, and high-energy beams 10 Properties and processing of polymers and reinforced plastics rapid prototyping and rapid tooling 11 Properties and processing of metal powders, ceramics, glasses, composites, and superconductors 12 Joining and fastening processes 13 Fabrication of microelectronic, micromechanical, and microelectromechanical devices nanomanufacturing 14 Automation of manufacturing processes and operations 15 Computer-integrated manufacturing systems 16 Product design and manufacturing in a global competitive environment
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TL;DR: Electrical discharge machining (EDM) has been continuously evolving from a mere tool and die making process to a micro-scale application machining alternative attracting a significant amount of research interests as mentioned in this paper.
Abstract: Electrical discharge machining (EDM) is a well-established machining option for manufacturing geometrically complex or hard material parts that are extremely difficult-to-machine by conventional machining processes. The non-contact machining technique has been continuously evolving from a mere tool and die making process to a micro-scale application machining alternative attracting a significant amount of research interests. In recent years, EDM researchers have explored a number of ways to improve the sparking efficiency including some unique experimental concepts that depart from the EDM traditional sparking phenomenon. Despite a range of different approaches, this new research shares the same objectives of achieving more efficient metal removal coupled with a reduction in tool wear and improved surface quality. This paper reviews the research work carried out from the inception to the development of die-sinking EDM within the past decade. It reports on the EDM research relating to improving performance measures, optimising the process variables, monitoring and control the sparking process, simplifying the electrode design and manufacture. A range of EDM applications are highlighted together with the development of hybrid machining processes. The final part of the paper discusses these developments and outlines the trends for future EDM research.
1,421 citations
TL;DR: In this paper, the authors provide an overview of machining induced surface integrity in titanium and nickel alloys and conclude that further modeling studies are needed to create predictive physics-based models that is in good agreement with reliable experiments.
Abstract: Titanium and nickel alloys represent a significant metal portion of the aircraft structural and engine components. When these critical structural components in aerospace industry are manufactured with the objective to reach high reliability levels, surface integrity is one of the most relevant parameters used for evaluating the quality of finish machined surfaces. The residual stresses and surface alteration (white etch layer and depth of work hardening) induced by machining of titanium alloys and nickel-based alloys are very critical due to safety and sustainability concerns. This review paper provides an overview of machining induced surface integrity in titanium and nickel alloys. There are many different types of surface integrity problems reported in literature, and among these, residual stresses, white layer and work hardening layers, as well as microstructural alterations can be studied in order to improve surface qualities of end products. Many parameters affect the surface quality of workpieces, and cutting speed, feed rate, depth of cut, tool geometry and preparation, tool wear, and workpiece properties are among the most important ones worth to investigate. Experimental and empirical studies as well as analytical and Finite Element modeling based approaches are offered in order to better understand machining induced surface integrity. In the current state-of-the-art however, a comprehensive and systematic modeling approach based on the process physics and applicable to the industrial processes is still missing. It is concluded that further modeling studies are needed to create predictive physics-based models that is in good agreement with reliable experiments, while explaining the effects of many parameters, for machining of titanium alloys and nickel-based alloys.
986 citations
Cites background from "Manufacturing Processes for Enginee..."
...Unless the metal is processed and kept in an inert (oxygen free) environment, or it is a noble metal, an oxide layer usually develops on top of the workhardened or amorphous layer [69]....
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TL;DR: In this paper, the authors proposed a method for machining aeroengine alloys with improved hardness, such as cubic boron nitride (CBN) tools, for high speed continuous machining.
970 citations
TL;DR: A survey of the current efforts in mechanical micro-machining research and applications, especially for micromilling operations, can be found in this paper, where the authors suggest areas from macro-milling that should be examined and researched for application to the improvement of micro-mechanical cutting processes.
Abstract: The miniaturization of machine components is perceived by many as a requirement for the future technological development of a broad spectrum of products. Miniature components can provide smaller footprints, lower power consumption and higher heat transfer, since their surface-to-volume ratio is very high. To create these components, micro-meso-scale fabrication using miniaturized mechanical material removal processes has a unique advantage in creating 3D components using a variety of engineering materials. The motivation for micro-mechanical cutting stems from the translation of the knowledge obtained from the macro-machining domain to the micro-domain. However, there are challenges and limitations to micro-machining, and simple scaling cannot be used to model the phenomena of micro-machining operations. This paper surveys the current efforts in mechanical micro-machining research and applications, especially for micro-milling operations, and suggests areas from macro-machining that should be examined and researched for application to the improvement of micro-machining processes.
690 citations
TL;DR: Additive manufacturing (AM) is the process of joining materials to make objects from 3D model data, usually layer by layer, is distinctly a different form and has many advantages over traditional manufacturing processes.
Abstract: Additive manufacturing (AM), the process of joining materials to make objects from three-dimensional (3D) model data, usually layer by layer, is distinctly a different form and has many advantages over traditional manufacturing processes. Commonly known as “3D printing,” AM provides a cost-effective and time-efficient way to produce low-volume, customized products with complicated geometries and advanced material properties and functionality. As a result of the 2013 National Science Foundation (NSF) Workshop on Frontiers of Additive Manufacturing Research and Education, this paper summarizes AM's current state, future potential, gaps and needs, as well as recommendations for technology and research, university–industry collaboration and technology transfer, and education and training.
688 citations
Cites background from "Manufacturing Processes for Enginee..."
...Educational materials on rapid prototyping have long been a part of manufacturing engineering courses at many engineering colleges, and some classical manufacturing textbooks, such as Manufacturing Processes for Engineering Materials by Kalpakjian and Schmid [15], have already included information on rapid prototyping, the precedent of AM....
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