The rapid growth of modern industry has resulted in a growing demand for construction materials with excellent operational properties. However, the improved features of these materials can significantly hinder their manufacture and, therefore, they can be defined as hard-to-cut. The main difficulties during the manufacturing/processing of hard-to-cut materials are attributed especially to their high hardness and abrasion resistance, high strength at room or elevated temperatures, increased thermal conductivity, as well as resistance to oxidation and corrosion. Nowadays, the group of hard-to-cut materials is extensive and still expanding, which is attributed to the development of a novel manufacturing techniques (e.g., additive technologies). Currently, the group of hard-to-cut materials mainly includes hardened and stainless steels, titanium, cobalt and nickel alloys, composites, ceramics, as well as the hard clads fabricated by additive techniques. This Special Issue, “Advances in Hard-to-Cut Materials: Manufacturing, Properties, Process Mechanics and Evaluation of Surface Integrity”, provides the collection of research papers regarding the various problems correlated with hard-to-cut materials. The analysis of these studies reveals the primary directions regarding the developments in manufacturing methods, characterization, and optimization of hard-to-cut materials.

The rapid growth of modern industry has resulted in a growing demand for construction materials with excellent operational properties. However, the improved features of these materials can significantly hinder their manufacture and, therefore, they can be defined as hard-to-cut. The main difficulties during the manufacturing/processing of hard-to-cut materials are attributed especially to their high hardness and abrasion resistance, high strength at room or elevated temperatures, increased thermal conductivity, as well as resistance to oxidation and corrosion. Nowadays, the group of hard-to-cut materials is extensive and still expanding, which is attributed to the development of a novel manufacturing techniques (e.g., additive technologies). Currently, the group of hard-to-cut materials mainly includes hardened and stainless steels, titanium, cobalt and nickel alloys, composites, ceramics, as well as the hard clads fabricated by additive techniques. This Special Issue, “Advances in Hard-to-Cut Materials: Manufacturing, Properties, Process Mechanics and Evaluation of Surface Integrity”, provides the collection of research papers regarding the various problems correlated with hard-to-cut materials. The analysis of these studies reveals the primary directions regarding the developments in manufacturing methods, characterization, and optimization of hard-to-cut materials.

Hard machining is a relatively recent technology that can be defined as a machining operation, using tools with geometrically defined cutting edges, of a work piece that has hardness values typically in the 45-70HRc range. This operation always presents the challenge of selecting a cutting tool insert that facilitates high-precision machining of the component, but it presents several advantages when compared with the traditional methodology based in finish grinding operations after heat treatment of work pieces. Machining of Hard Materials aims to provide the reader with the fundamentals and recent advances in the field of hard machining of materials. All the chapters are written by international experts in this important field of research. They cover topics such as: • advanced cutting tools for the machining of hard materials; • the mechanics of cutting and chip formation; • surface integrity; • modelling and simulation; and • computational methods and optimization. Machining of Hard Materials can serve as a useful reference for academics, manufacturing and materials researchers, manufacturing and mechanical engineers, and professionals in machining and related industries. It can also be used as a text for advanced undergraduate or postgraduate students studying mechanical engineering, manufacturing, or materials.

Laser Machining: Theory and Practice addresses state-of-the-art laser machining in a way useful for research- ers, academicians and practitioners, particularly manufacturing engineers, who are considering lasers as a solution to the machining requirements of their factories and plants. This book provides detailed information on the theory behind laser machining, as well as its requirements, uses and applications. In order to place laser machining in its correct context, the author begins with an overview of conventional material removal processes and go on to describe in detail the physical mechanisms involved in lasers, the different types of lasers involved in laser machining, and laser machining systems, which include optics, positioning systems, manipulators, etc. The theoretical treatment of the laser includes a section on the basics of heat transfer and fluid mechanics, and analyses of one, two and three-dimensional laser machining processes. The book closes with a description of state-of-the-art laser machining applications in research and industrial practice.

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

Metal cutting is a science and technology of great interest for several important industries, such as automotive, aeronautics, aerospace, moulds and dies, biomedicine, etc. Metal cutting is a manufacturing process in which parts are shaped by removal of unwanted material. The interest for this topic increased over the last twenty years, with rapid advances in materials science, automation and control, and computers technology. The present volume aims to provide research developments in metal cutting for modern industry. This volume can be used by students, academics, researchers, and engineering professionals in mechanical, manufacturing, and materials industries. THE SERIES: ADVANCED MECHANICAL ENGINEERING Currently, it is possible to defi ne mechanical engineering as the branch of engineering that “involves the application of principles of physics and engineering for the design, manufacturing, automation and maintenance of mechanical systems”. Mechanical Engineering is closely related to a number of other engineering disciplines. This series fosters information exchange and discussion on all aspects of mechanical engineering with a special emphasis on research and development from a number of perspectives including (but not limited to) materials and manufacturing processes, machining and machine tools, tribology and surface engineering, structural mechanics, applied and computational mechanics, mechanical design, mechatronics and robotics, fluid mechanics and heat transfer, renewable energies, biomechanics, nanoengineering and nanomechanics. In addition, the series covers the full range of sustainability aspects related with mechanical engineering. Advanced Mechanical Engineering is an essential reference for students, academics, researchers, materials, mechanical and manufacturing engineers and professionals in mechanical engineering.

This book presents a balanced blend of fundamental research such as principles and characteristics of machining of difficult-to-cut materials and coating techniques and in-depth practical information on coatings techniques and classifications, the effect of coating parameters on machining responses, and finite element analysis of the machining performance of coated tools. In addition to the benefits of the thin-film deposition on the cutting tools, the limitations of the coating deposition techniques and the coating properties are also discussed. Features: Associates the application of coating technology for improving machining characteristics of difficult-to-cut materials Elaborates effect of coating architecture on the output machining parameters Explores the performance of coated cutting tools Discusses advanced coating systems and their application Includes industrial case studies and practical implementations where coatings were applied for the machining of difficult-to-cut materials This book is aimed at researchers and graduate students in thin-films, coatings, machining, materials engineering, and manufacturing.

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.

Metal machining is the most widespread metal-shaping process in the mechanical manufacturing industry. World-wide investment in metal machining tools increases year on year - and the wealth of nations can be judged by it. This text - the most up-to-date in the field - provides in-depth discussion of the theory and application of metal machining at an advanced level. It begins with an overview of the development of metal machining and its role in the current industrial environment and continues with a discussion of the theory and practice of machining. The underlying mechanics are analysed in detail and there are extensive chapters examining applications through a discussion of simulation and process control. "Metal Machining: Theory and Applications" is essential reading for senior undergraduates and postgraduates specialising in cutting technology. It is also an invaluable reference tool for professional engineers. Professors Childs, Maekawa, Obikawa and Yamane are four of the leading authorities on metal machining and have worked together for many years.Of interest to all mechanical, manufacturing and materials engineersTheoretical and practical problems addressed

This book presents the potential applications of hard materials as well as the latest trends and challenges in machining hard materials. Models for online monitoring to adjust parameters to obtain desired machining characteristics (i.e. reverse modelling) are discussed in this book. The conflicting requirements (i.e. maximize: material removal rate, roundness and minimize: surface roughness, dimensional ovality, co axiality, tool wear) in machining for industry personal is solved using advanced optimization tools. In addition, the framework for experimental modelling, predictive physic-based forward and reverse process models and optimization for better machining characteristics applicable to industry are proposed.