| Metal Cutting Mechanics, Finite Element Modelling | p. 1 |
| Advanced Metal Cutting Mechanics | p. 1 |
| Objective of Metal Cutting Mechanics | p. 1 |
| State of the Art | p. 1 |
| Advanced Methodology | p. 4 |
| Combined Influence of the Minor Cutting Edge | p. 7 |
| Influence of the Cutting Speed, Depth of Cut and Cutting Feed on Power Partition | p. 9 |
| Concluding Remarks | p. 11 |
| Finite Element Analysis (FEA) | p. 13 |
| Numerical Formulations | p. 14 |
| Modelling Chip Separation from the Workpiece and Chip Segmentation | p. 15 |
| Mesh Design | p. 16 |
| Work Material Modelling | p. 18 |
| Modelling of Contact Conditions | p. 19 |
| Numerical Integration | p. 19 |
| Errors | p. 20 |
| Example | p. 20 |
| Advanced Numerical Modelling | p. 21 |
| Model Validation | p. 22 |
| References | p. 25 |
| Tools (Geometry and Material) and Tool Wear | p. 29 |
| Essentials of Tool Geometry | p. 29 |
| Importance of the Cutting Tool Geometry | p. 29 |
| Basic Terms and Definitions | p. 31 |
| System of Considerations | p. 32 |
| Basic Tool Geometry Components | p. 33 |
| Influence of the Tool Angles | p. 35 |
| Tool Materials | p. 37 |
| Carbides | p. 39 |
| Ceramics | p. 43 |
| Cubic Boron Nitride (CBN) | p. 44 |
| Polycrystalline Diamond (PCD) and Solid Film Diamond (SFD) | p. 45 |
| Tool Wear | p. 48 |
| Tool Wear Types | p. 48 |
| Tool Wear Evolution | p. 50 |
| Mechanisms of Tool Wear | p. 52 |
| Tool Life | p. 52 |
| Taylor's Tool Life Formula | p. 53 |
| Expanded Taylor's Tool Life Formula | p. 55 |
| Recent Trends in Tool Life Evaluation | p. 55 |
| References | p. 57 |
| Workpiece Surface Integrity | p. 59 |
| What Does Surface Integrity Mean? | p. 59 |
| Link Between Surface Integrity and its Manufacturing Procedure | p. 62 |
| Impact of the Surface Integrity on the Dimensional Accuracy | p. 64 |
| Impact of the Surface Integrity on Fatigue Resistance | p. 67 |
| Material and Mechanical Aspects of Surface Integrity | p. 68 |
| Mechanisms Leading to Material and Mechanical Modifications in Machining | p. 68 |
| Modelling of Residual Stresses | p. 74 |
| Experimental Approach | p. 80 |
| References | p. 91 |
| Machining of Hard Materials | p. 97 |
| Basic Features of HM | p. 97 |
| Definition of Hard Machining | p. 97 |
| Comparison with Grinding Operations | p. 98 |
| Technological Processes Including Hard Machining | p. 100 |
| Equipment and Tooling | p. 101 |
| Machine Tools | p. 101 |
| Cutting Tools and Materials | p. 102 |
| Complete Machining Using Hybrid Processes | p. 104 |
| Characterization of Hard Machining Processes | p. 105 |
| Cutting Forces | p. 105 |
| Chip Formation | p. 105 |
| Cutting Temperature | p. 108 |
| Wear of Ceramic and PCBN Tools | p. 110 |
| Modelling of Hard Cutting Processes | p. 110 |
| Surface Integrity in Hard Machining Processes | p. 113 |
| Surface Roughness | p. 113 |
| Residual Stresses | p. 114 |
| Micro/Nanohardness Distribution and White-Layer Effect | p. 115 |
| Modification of Surface Finish in Hybrid Processes | p. 117 |
| Cutting Errors and Dimensional Accuracy | p. 118 |
| Applications of Hard Machining Processes | p. 119 |
| Hard Turning | p. 119 |
| Hard and High-Speed Milling of Dies and Moulds | p. 120 |
| Hard Reaming | p. 121 |
| Hard Broaching | p. 122 |
| Hard Skive Hobbing | p. 122 |
| Optimization of Hard Machining Processes | p. 123 |
| References | p. 124 |
| Machining of Particulate-Reinforced Metal Matrix Composites | p. 127 |
| Introduction | p. 127 |
| Effect of Reinforcement Particles on Surface Integrity and Chip Formation | p. 129 |
| Strength of MMC During Machining | p. 130 |
| Chip Shape | p. 131 |
| Surface Integrity | p. 135 |
| Shear and Friction Angles | p. 142 |
| Relation Between Shear and Friction Angles | p. 144 |
| Forces | p. 145 |
| Modelling | p. 147 |
| Forces | p. 147 |
| Tool-Particle Interaction | p. 157 |
| Tool Wear | p. 159 |
| Performance of Cutting Tools | p. 159 |
| Modelling of Tool Wear | p. 161 |
| Acknowledgements | p. 162 |
| References | p. 162 |
| Drilling Polymeric Matrix Composites | p. 167 |
| Introduction | p. 167 |
| What Are Polymeric Matrix Composites? | p. 167 |
| The Importance of Drilling | p. 171 |
| Drilling Technology of Polymeric Matrix Composites | p. 173 |
| Conventional Drilling Process | p. 173 |
| Unconventional Drilling Processes | p. 178 |
| Modelling of Conventional Drilling | p. 179 |
| The Need for Modelling | p. 179 |
| Cutting Force Modelling | p. 180 |
| Damage Generated During Drilling and Residual Mechanical Properties | p. 183 |
| Structural Damage | p. 183 |
| Residual Mechanical Properties | p. 186 |
| Damage Suppression Methods | p. 188 |
| Introduction | p. 188 |
| Process Parameters Selection | p. 188 |
| Drilling Conditions | p. 189 |
| Special Tools | p. 190 |
| References | p. 191 |
| Ecological Machining: Near-dry Machining | p. 195 |
| Introduction | p. 195 |
| Amount and Cost | p. 196 |
| Health and Environmental Aspects | p. 197 |
| Principal Directions in the Reduction of MWF Economical, Ecological and Health Impacts | p. 198 |
| Nearly Dry Machining (NDM) | p. 201 |
| How NDM Operates | p. 201 |
| Classification of NDM | p. 202 |
| Why NDM Works | p. 212 |
| Consideration of the NDM System Components | p. 217 |
| References | p. 221 |
| Sculptured Surface Machining | p. 225 |
| Introduction | p. 225 |
| The Manufacturing Process | p. 227 |
| Technologies Involved | p. 228 |
| Five-axis Milling | p. 229 |
| The CAM, Centre of Complex Surfaces Production | p. 231 |
| Workpiece Precision | p. 233 |
| Cutting Forces | p. 235 |
| Workpiece Roughness | p. 237 |
| Tool Path Selection Using Cutting Force Prediction | p. 239 |
| Three-axis Case | p. 240 |
| Five-axis Case | p. 241 |
| Examples | p. 242 |
| Three-axis Mould | p. 242 |
| Five-axis Mould | p. 243 |
| Three-axis Deep Mould | p. 245 |
| Present and Future | p. 246 |
| Acknowledgements | p. 246 |
| References | p. 247 |
| Grinding Technology and New Grinding Wheels | p. 249 |
| Introduction | p. 249 |
| High-efficiency Grinding Using Conventional Abrasive Wheels | p. 250 |
| Introduction | p. 250 |
| Grinding Wheel Selection | p. 251 |
| Grinding Machine Requirements for High-efficiency Dressing | p. 253 |
| Diamond Dressing Wheels | p. 253 |
| Application of Diamond Dressing Wheels | p. 256 |
| Modifications to the Grinding Process | p. 257 |
| Selection of Grinding Process Parameters | p. 257 |
| Selection of Cooling Lubricant Type and Application | p. 258 |
| High-efficiency Grinding Using CBN Grinding Wheels | p. 258 |
| Introduction | p. 258 |
| Grinding Wheel Selection | p. 259 |
| Grinding Machine Requirements for High-efficiency CBN Grinding | p. 264 |
| Dressing High-efficiency CBN Grinding Wheels | p. 265 |
| Selection of Dressing Parameters for High-efficiency CBN Grinding | p. 266 |
| Selection of Cooling Lubrication for High-efficiency CBN Grinding Wheels | p. 266 |
| Internet Resources | p. 267 |
| References | p. 269 |
| Micro and Nanomachining | p. 271 |
| Introduction | p. 271 |
| Machining Effects at the Microscale | p. 272 |
| Shear Angle Prediction | p. 275 |
| Plastic Behaviour at Large Strains | p. 278 |
| Langford and Cohen's Model | p. 278 |
| Walker and Shaw's Model | p. 279 |
| Usui's Model | p. 280 |
| Saw-tooth Chip Formation in Hard Turning | p. 281 |
| Fluid-like Flow in Chip Formation | p. 281 |
| Size Effects in Micromachining | p. 282 |
| Nanomachining | p. 282 |
| Nanometric Machining | p. 283 |
| Theoretical Basis of Nanomachining | p. 284 |
| Comparison of Nanometric Machining and Conventional Machining | p. 294 |
| Acknowledgements | p. 295 |
| References | p. 295 |
| Advanced (Non-traditional) Machining Processes | p. 299 |
| Introduction | p. 299 |
| Mechanical Advanced Machining Processes (MAMP) | p. 301 |
| Ultrasonic Machining (USM) | p. 301 |
| Abrasive Water Jet Cutting (AWJC) | p. 304 |
| Thermoelectric Advanced Machining Processes | p. 307 |
| Electric Discharge Machining (EDM) and Wire EDM | p. 307 |
| Laser Beam Machining (LBM) | p. 312 |
| Electrochemical Advanced Machining Processes | p. 313 |
| Electrochemical Machining (ECM) | p. 313 |
| ECM Machine | p. 315 |
| Fine Finishing Processes | p. 317 |
| Abrasive Flow Machining (AFM) | p. 317 |
| Magnetic Abrasive Finishing (MAF) | p. 320 |
| Magnetic Float Polishing (MFP) | p. 323 |
| Micromachining | p. 324 |
| Finished Surface Characteristics | p. 325 |
| References | p. 325 |
| Intelligent Machining: Computational Methods and Optimization | p. 329 |
| Intelligent Machining | p. 329 |
| Neural Network Modelling | p. 332 |
| Fuzzy Set Theory | p. 339 |
| Neuro-fuzzy Modelling | p. 344 |
| A Note on FEM Modelling | p. 347 |
| Machining Optimization | p. 348 |
| Objective Functions and Constraints | p. 348 |
| Optimization Techniques | p. 350 |
| Future Challenges | p. 355 |
| References | p. 356 |
| Index | p. 359 |
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