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Machining Difficult-to-Cut Materials Basic Principles and Challenges

:	Hossam A. Kishawy, Ali Hosseini
:	Machining Difficult-to-Cut Materials Basic Principles and Challenges
:	Springer-Verlag
:	9783319959665
:	1
:	CHF 143.10
:

:	Maschinenbau, Fertigungstechnik
:	English

:	253
:	Wasserzeichen/DRM
:	PC/MAC/eReader/Tablet
:	PDF

This book focus on the challenges faced by cutting materials with superior mechanical and chemical characteristics, such as hardened steels, titanium alloys, super alloys, ceramics and metal matrix composites. Aspects such as costs and appropriate machining strategy are mentioned. The authors present the characteristics of the materials difficult to cut and comment on appropriate cutting tools for their machining. This book also serves as a reference tool for manufacturers working in industry.

	Preface	6
	Contents	8
	1 Introduction	14
	Abstract	14
	1.1 Historical Background	14
	1.1.1 Stone Age	14
	1.1.2 Bronze Age	15
	1.1.3 Iron Age	16
	1.2 Modern Engineering Materials	17
	1.2.1 Steels	18
	1.2.2 Titanium and Its Alloys	18
	1.2.3 Superalloys	19
	1.2.4 Metal Matrix Composites (MMCs)	19
	1.2.5 Ceramics	19
	1.3 Superior Characteristics, Major Challenges	20
	Reference	20
	2 Hardened Steels	21
	Abstract	21
	2.1 Introduction	21
	2.1.1 Heat Treatment	22
	2.1.2 Cryogenic Treatment	23
	2.1.3 Case Hardening	24
	2.1.3.1 Carburizing	24
	2.1.3.2 Gas Nitriding	25
	2.1.3.3 Induction Hardening	25
	2.1.3.4 Flame Hardening	25
	2.2 Historical Background and Evolution of Hardened Steels	26
	2.3 Metallurgy of Hardened Steels	28
	2.4 Characteristics of Hardened Steels	31
	2.4.1 High Indentation Hardness	31
	2.4.2 Low Ductility (Brittleness)	31
	2.4.3 High Hardness/E-modulus Ratio	31
	2.4.4 Corrosion Sensitivity	32
	2.5 Industrial Applications of Hardened Steels	32
	2.5.1 Applications of Case-Hardened Steels	33
	2.5.2 Applications of Induction Hardened Steels	33
	2.5.3 Applications of Carburized Steels	34
	2.6 Challenges in the Machining of Hardened Steels	35
	2.7 Hard Turning	37
	2.7.1 Hard Turning as an Alternative for Grinding	38
	2.7.2 Special Features of Hard Turning	39
	2.7.3 Rigidity Imposed Limitations in Hard Turning	41
	2.7.4 Surface Quality and Integrity	41
	2.7.4.1 Formation of White Layer	41
	2.7.4.2 Residual Stresses	44
	2.7.4.3 Material Side Flow	45
	2.8 Mechanics of Chip Formation During Hard Turning	46
	2.9 Influential Factors on Chip Formation During Hard Turning	50
	2.9.1 Nose Radius	50
	2.9.2 Edge Preparation and Tool Condition	50
	2.9.3 Feed	51
	2.10 Dynamics of Chip Formation	54
	2.11 Cutting Forces During Hard Turning	55
	2.12 Appropriate Tool Materials for Hard Turning	56
	2.12.1 CBN and PCBN Tools	57
	2.12.2 Ceramic Tools	60
	2.12.3 Cermet (Solid Titanium Carbide) Tools	61
	2.13 Surface Finish in Hard Turning	62
	2.14 Environmentally Friendly Hard Turning	63
	2.15 Hard Milling	63
	2.16 Concluding Remarks	64
	References	64
	3 Titanium and Titanium Alloys	67
	Abstract	67
	3.1 Introduction	67
	3.2 Historical Background and Evolution of Titanium	69
	3.3 Metallurgy of Titanium	71
	3.3.1 Alpha (?) Alloys	73
	3.3.2 Near-Alpha (?) Alloys	73
	3.3.3 Alpha-Beta (??+??) Alloys	74
	3.3.4 Metastable Beta (?) Alloys	74
	3.3.5 Beta (?) Alloys	75
	3.3.6 Titanium Aluminides	75
	3.4 Characteristics of Titanium and Its Alloys	76
	3.5 Industrial Applications of Titanium and Its Alloys	80
	3.5.1 Aerospace Applications	80
	3.5.2 Chemical and Petrochemical Applications	83
	3.5.3 Automotive Applications	84
	3.6 Challenges in the Machining of Titanium and Its Alloys	86
	3.6.1 Poor Thermal Conductivity	87
	3.6.2 Chemical Reactivity	89
	3.6.3 Low Modulus of Elasticity	89
	3.6.4 Hardening Effect	90
	3.7 Mechanics of Chip Formation	90
	3.7.1 Chip Segmentation Under Adiabatic Shear	92
	3.8 Appropriate Tool Materials and Modes of Tool Wear	97
	3.8.1 HSS Tools	98
	3.8.2 Carbide Tools	99
	3.8.3 Ceramic Tools	101
	3.8.4 CBN and PCBN Tools	101
	3.8.5 Diamond Tools	102
	3.9 Application of Coolant in the Machining of Titanium	103
	3.9.1 Utilization of Nano-cutting Fluids	104
	3.10 Concluding Remarks	105
	References	106
	4 Superalloys	109
	Abstract	109
	4.1 Introduction	109
	4.2 Historical Background and Evolution of Superalloys	111
	4.3 Metallurgy of Superalloys	115
	4.3.1 Phases of Superalloys	117
	4.3.1.1 Gamma (?) Phase	117
	4.3.1.2 Gamma Prime (??) Phase	117
	4.3.1.3 Gamma Double Prime (??) Phase	118
	4.3.1.4 Carbides	118