Metal removal processes - cutting and grinding in this book - are an integral part of a large number of manufacturing systems, either as the primary manufacturing process, or as an important part of preparing the tooling for other manufacturing processes. In recent years, industry and educational institutions have concentrated on the metal removal system, perhaps at the expense of the process. This book concentrates on metal removal processes, particularly on the modeling aspects that can either give a direct answer or suggest the general requirements as to how to control, improve or change a metal removal process. This modeling knowledge is more important with automated computer controlled systems than it has ever been before, because quantitative knowledge is needed to design and operate these systems. This senior undergraduate/graduate textbook is aimed at providing the quantitative knowledge, often times at an elementary level, for handling the technological aspects of setting up and operating a metal removal process and interpreting the experience of planning, operating and improving a metal removal process based on rule of thumb approaches.

Machining is one of the eight basic manufacturing processes. This textbook covers the fundamentals and engineering analysis of both conventional and advanced/non-traditional material removal processes along with gear cutting/manufacturing and computer numerically controlled (CNC) machining. The text provides a holistic understanding of machining processes and machines in manufacturing; it enables critical thinking through mathematical modeling and problem solving, and offers 200 worked examples/calculations and 70 multiple choice questions on machining operations, as well as on CNC machining, with the eBook version offered in color. This unique book is equally useful to both engineering degree students and production engineers practicing in the manufacturing industry.

The text comprehensively focuses on the concepts, implementation, and application of evolutionary algorithms for predicting, modeling, and optimizing the various material removal processes from their origin to the current advancements. This one-of-a-kind book encapsulates all the features related to the application and implementation of evolutionary algorithms for the purpose of predicting and optimizing the process characteristics of different machining methods and their allied processes that will provide comprehensive information. It broadly explains the concepts of employing evolutionary algorithm-based optimization in a broad domain of various material removal processes. Therefore, this book will enable prospective readers to take full advantage of recent findings and advancements in the fields of traditional, advanced, micro, and hybrid machining, among others. Moreover, the simplicity of its writing will keep readers engaged throughout and make it easier for them to understand the advanced topics. The book- • Offers a step-by-step guide to implement evolutionary algorithms for the overall optimization of conventional and contemporary machining processes • Provides in-depth analysis of various material removal processes through evolutionary optimization • Details an overview of different evolutionary optimization techniques • Explores advanced processing of various engineering materials-based case studies It further discusses different nature-inspired algorithms-based modeling, prediction, and modeling of machining responses in attempting advanced machining of the latest materials and related engineering problems along with case studies and practical examples. It will be an ideal reference text for graduate students and academic researchers working in the fields of mechanical engineering, aerospace engineering, industrial engineering, manufacturing engineering, and materials science.

This book provides readers with the fundamental, analytical, and quantitative knowledge of machining process planning and optimization based on advanced and practical understanding of machinery, mechanics, accuracy, dynamics, monitoring techniques, and control strategies that they need to understanding machining and machine tools. It is written for first-year graduate students in mechanical engineering, and is also appropriate for use as a reference book by practicing engineers. It covers topics such as single and multiple point cutting processes; grinding processes; machine tool components, accuracy, and metrology; shear stress in cutting, cutting temperature and thermal analysis, and machine tool chatter. The second section of the book is devoted to “Non-Traditional Machining,” where readers can find chapters on electrical discharge machining, electrochemical machining, laser and electron beam machining, and biomedical machining. Examples of realistic problems that engineers are likely to face in the field are included, along with solutions and explanations that foster a didactic learning experience.

Results of work for the development of methodologies for mathematical modeling and economic analysis of material removal processes and presented. Initially, an extensive literature review was conducted to identify the major unsolved problem areas and to examine the necessary techniques for their solution. The major problems identified were: (1) the selection of levels and positions of independent variables during the planning of experiments; (2) definition of the working region within which the model is valid, and (3) incorporation of variable radial depth and/or feed during a given cut. A methodology for solving problems (1) and (2) was developed and verified through analysis of available machining data from end milling tests (Contract No. F33615-74-C-5025) and from turning (Contract No. F33615-73-C-5180). A series of end milling tests with variable radial depth and/or feed were conducted to determine the effect of in-process changes in machining variables on tool wear and tool life. Shop floor validation of the laboratory data was carried out. Economic analysis for process design, planning and optimization was conducted through the development of macro-economic and microeconomic models.

An undergraduate text for engineers studying materials science, this book deals with the basic principles in a simple yet meaningful manner. Updated throughout and with new diagrams and photographs in this fourth edition, this continues to be a popular text with students and lecturers alike.