A program has been run to evaluate the effects of different metal removal methods and variations of these methods on surface integrity. Three alloys were studied: beta rolled Ti-6Al-4V; AISI 4340, quenched and tempered, 50 Rc; and Inconel 718, solution treated and aged. Various grinding procedures caused the titanium alloy to exhibit a fatigue strength range of 13 to 62 ksi. The fatigue strength of 4340 due to grinding variables ranged from 62 to 102 ksi, while Inconel 718 showed a range of 24 to 60 ksi. Abusive grinding conditions always resulted in fatigue strengths at the minimum of these ranges. Milling variables exhibited a fatigue strength range of 32 to 72 ksi in the beta rolled titanium alloy. EDM and ECM on Inconel 718 yielded 22 and 39 ksi, respectively, compared to 60 ksi for gentle grinding. Guidelines for processing aerospace hardware considering surface integrity requirements are presented in the report.

"Surface Integrity in Machining" describes the fundamentals and recent advances in the study of surface integrity in machining processes. "Surface Integrity in Machining" gathers together research from international experts in the field. Topics covered include: the definition of surface integrity and its importance in functional performance; surface topography characterization and evaluation; microstructure modification and the mechanical properties of subsurface layers; residual stresses; surface integrity characterization methods; and surface integrity aspects in machining processes. A useful reference for researchers in tribology and materials, mechanical and materials engineers, and machining professionals, "Surface Integrity in Machining" can be also used as a textbook by advanced undergraduate and postgraduate students.

A surface integrity evaluation of several iron, titanium and nickel base structural alloys was completed. Materials investigated include AISI 4340, 4340 modified, Grade 300 Maraging Steel, Ti-6Al-6V-2Sn, Ti-6Al-2Sn-4Zr-2Mo, Inconel 718, AF95, Rene' 80 and AF2-1DA. For the most part, these alloys were quenched and tempered or solution treated and aged, as appropriate, to put them into a high strength structural condition. Wide variations in fatigue strength were documented for the above mentioned alloys under the following metal removal conditions: surface grinding, hand sanding, end milling-peripheral cutting, end milling-end cutting, EDM and ECM. Guidelines for processing of aerospace hardware in such a way as to assure good surface integrity have been developed and presented in this report. Control of cutting tool sharpness as well as proper selection of processing parameters are prime requirements.

Advanced Machining Processes of Metallic Materials: Theory, Modelling and Applications, Second Edition, explores the metal cutting processes with regard to theory and industrial practice. Structured into three parts, the first section provides information on the fundamentals of machining, while the second and third parts include an overview of the effects of the theoretical and experimental considerations in high-level machining technology and a summary of production outputs related to part quality. In particular, topics discussed include: modern tool materials, mechanical, thermal and tribological aspects of machining, computer simulation of various process phenomena, chip control, monitoring of the cutting state, progressive and hybrid machining operations, as well as practical ways for improving machinability and generation and modeling of surface integrity. This new edition addresses the present state and future development of machining technologies, and includes expanded coverage on machining operations, such as turning, milling, drilling, and broaching, as well as a new chapter on sustainable machining processes. In addition, the book provides a comprehensive description of metal cutting theory and experimental and modeling techniques, along with basic machining processes and their effective use in a wide range of manufacturing applications. The research covered here has contributed to a more generalized vision of machining technology, including not only traditional manufacturing tasks, but also potential (emerging) new applications, such as micro and nanotechnology. - Includes new case studies illuminate experimental methods and outputs from different sectors of the manufacturing industry - Presents metal cutting processes that would be applicable for various technical, engineering, and scientific levels - Includes an updated knowledge of standards, cutting tool materials and tools, new machining technologies, relevant machinability records, optimization techniques, and surface integrity

Machining of Metal Matrix Composites provides the fundamentals and recent advances in the study of machining of metal matrix composites (MMCs). Each chapter is written by an international expert in this important field of research. Machining of Metal Matrix Composites gives the reader information on machining of MMCs with a special emphasis on aluminium matrix composites. Chapter 1 provides the mechanics and modelling of chip formation for traditional machining processes. Chapter 2 is dedicated to surface integrity when machining MMCs. Chapter 3 describes the machinability aspects of MMCs. Chapter 4 contains information on traditional machining processes and Chapter 5 is dedicated to the grinding of MMCs. Chapter 6 describes the dry cutting of MMCs with SiC particulate reinforcement. Finally, Chapter 7 is dedicated to computational methods and optimization in the machining of MMCs. Machining of Metal Matrix Composites can serve as a useful reference for academics, manufacturing and materials researchers, manufacturing and mechanical engineers, and professionals involved with MMC applications. It can also be used to teach modern manufacturing engineering or as a textbook for advanced undergraduate and postgraduate engineering courses in machining, manufacturing or materials.