The United States now spends approximately $115 billion annually to perform its metal removal tasks using conventional machining technology. Of this total amount, about $14 billion is invested in the aerospace and associated industries. It becomes clear that metal removal technology is a very important candidate for rigorous investigation looking toward improvement of productivity within the manufacturing system. To aid in this endeavor, work has begun to establish a new scientific and technical base that will provide principles upon which manufacturing decisions may be based. One of the metal removal areas that has the potential for great economic advantages is high-speed machining and related technology. This text is concerned with discussions of ways in which high-speed machining systems can solve immediate problems of profiling, pocketing, slotting, sculpturing, facing, turning, drilling, and thin-walled sectioning. Benefits to many existing programs are provided by aiding in solving a current management production problem, that of efficiently removing large volumes of metal by chip removal. The injection of new high-rate metal removal techniques into conventional production procedures, which have remained basically unchanged for a century, presents a formidable systems problem, both technically and man agerially.The proper solution requires a sophisticated, difficult process whereby management-worker relationships are reassessed, age-old machine deSigns reevaluated, and a new vista of product/process planning and design admitted.

It is a well acknowledged fact that virtually all of our modern-day components and assemblies rely to some extent on machining operations in their manufacturing process. Thus, there is clearly a substantive machining requirement which will continue to be of prime importance for the foreseeable future. Cutting Tool Technology provides a comprehensive guide to the latest developments in the use of cutting tool technology. The book covers new machining and tooling topics such as high-speed and hard-part machining, near-dry and dry-machining strategies, multi-functional tooling, ‘diamond-like’ and ‘atomically-modified’ coatings, plus many others. Also covered are subjects important from a research perspective, such as micro-machining and artificial intelligence coupled to neural network tool condition monitoring. A practical handbook complete with troubleshooting tables for common problems, Cutting Tool Technology is an invaluable reference for researchers, manufacturers and users of cutting tools.

A Complete Reference Covering the Latest Technology in Metal Cutting Tools, Processes, and Equipment Metal Cutting Theory and Practice, Third Edition shapes the future of material removal in new and lasting ways. Centered on metallic work materials and traditional chip-forming cutting methods, the book provides a physical understanding of conventional and high-speed machining processes applied to metallic work pieces, and serves as a basis for effective process design and troubleshooting. This latest edition of a well-known reference highlights recent developments, covers the latest research results, and reflects current areas of emphasis in industrial practice. Based on the authors’ extensive automotive production experience, it covers several structural changes, and includes an extensive review of computer aided engineering (CAE) methods for process analysis and design. Providing updated material throughout, it offers insight and understanding to engineers looking to design, operate, troubleshoot, and improve high quality, cost effective metal cutting operations. The book contains extensive up-to-date references to both scientific and trade literature, and provides a description of error mapping and compensation strategies for CNC machines based on recently issued international standards, and includes chapters on cutting fluids and gear machining. The authors also offer updated information on tooling grades and practices for machining compacted graphite iron, nickel alloys, and other hard-to-machine materials, as well as a full description of minimum quantity lubrication systems, tooling, and processing practices. In addition, updated topics include machine tool types and structures, cutting tool materials and coatings, cutting mechanics and temperatures, process simulation and analysis, and tool wear from both chemical and mechanical viewpoints. Comprised of 17 chapters, this detailed study: Describes the common machining operations used to produce specific shapes or surface characteristics Contains conventional and advanced cutting tool technologies Explains the properties and characteristics of tools which influence tool design or selection Clarifies the physical mechanisms which lead to tool failure and identifies general strategies for reducing failure rates and increasing tool life Includes common machinability criteria, tests, and indices Breaks down the economics of machining operations Offers an overview of the engineering aspects of MQL machining Summarizes gear machining and finishing methods for common gear types, and more Metal Cutting Theory and Practice, Third Edition emphasizes the physical understanding and analysis for robust process design, troubleshooting, and improvement, and aids manufacturing engineering professionals, and engineering students in manufacturing engineering and machining processes programs.

High-Speed Machining covers every aspect of this important subject, from the basic mechanisms of the technology, right through to possible avenues for future research. This book will help readers choose the best method for their particular task, how to set up their equipment to reduce chatter and wear, and how to use simulation tools to model high-speed machining processes. The different applications of each technology are discussed throughout, as are the latest findings by leading researchers in this field. For any researcher looking to understand this topic, any manufacturer looking to improve performance, or any manager looking to upgrade their plant, this is the most comprehensive and authoritative guide available. - Summarizes important R&D from around the world, focusing on emerging topics like intelligent machining - Explains the latest best practice for the optimization of high-speed machining processes for greater energy efficiency and machining precision - Provides practical advice on the testing and monitoring of HSM machines, drawing on practices from leading companies

Machining and cutting technologies are still crucial for many manufacturing processes. This reference presents all important machining processes in a comprehensive and coherent way. It provides the practising engineer with many technical information of the manufacturing processes and collects essential aspects such as maximum obtainable precision, errors or reference values. Many examples of concrete calculations, problems and their solutions illustrate the material and support the learning reader. The internet addresses given in the appendix provide with a fast link to more information sources.

The latest information indicates that the United States now spends in excess of $150 billion annually to perform its metal removal tasks using conventional machining technology. That estimate is increased from $115 billion 5 years ago. It becomes clear that metal removal technology is a very important candidate for rigorous investigation looking toward improvement of productivity within the manufacturing system. To aid in that endeavor, an extensive program of research has developed within the industrial community with the express purpose of establishing a new scientific and applied base that will provide principles upon which new manufacturing decisions can be made. One of the metal removal techniques that has the potential for great economic advantages is high-rate metal removal with related technologies. This text is concerned with the field of grinding as a subset of the general field of high-rate metal removal. Related processes (not covered in this text) include such topics as turning, drilling, and milling. In the final evaluation, the correct decision in the determination of a grinding process must necessarily include an understanding of the other methods of metal removal. The term grinding, as used herein, includes polishing, buffing, lapping, and honing as well as conventional definition: "... removing either metallic or other materials by the use of a solid grinding wheel".