Manufacturing is the basic industrial activity generating real value. Cutting and abrasive technologies are the backbone of precision production in machine, automotive and aircraft building as well as of production of consumer goods. We present the knowledge of modern manufacturing in these technologies on the basis of scientific research. The theory of cutting and abrasive processes and the knowledge about their application in industrial practice are a prerequisite for the studies of manufacturing science and an important part of the curriculum of the master study in German mechanical engineering. The basis of this book is our lecture “Basics of cutting and abrasive processes” (4 semester hours/3 credit hours) at the Leibniz University Hannover, which we offer to the diploma and master students specializing in manufacturing science.

This new edition draws upon the fundamentals of abrasive machining processes and the science of tribology to understand, predict, and improve abrasive machining processes. Each of the main elements of the abrasive machining system is looked at alongside the tribological factors that control the efficiency and quality of the processes described. The new edition has been updated to include a variety of industrial applications. Grinding and conditioning of grinding tools are dealt with in particular detail, and solutions are proposed for many of the most commonly experienced industrial problems, such as poor accuracy, poor surface quality, rapid tool wear, vibrations, workpiece burn, and high process costs. The entire book has been rewritten and restructured, with ten completely new chapters. Other new features include: Extensive explanations of the main abrasive machining processes such as grinding (including reciprocating and creep-feed grinding, high-speed high-efficiency deep grinding, external and internal cylindrical grinding, and centerless grinding), honing, superfinishing, lapping, polishing, and finishing Discussions of the new classes of abrasives, abrasive tools, and bonding materials New case studies and troubleshooting on the most common grinding practices New coverage on grinding tool conditioning, mechanical dressing, and nonmechanical dressing processes Detailed explanations of the effects of process input parameters (such as cutting parameters, workpiece material and geometry, and abrasive tools) on process characteristics, workpiece quality, tool wear, and process parameters (such as cutting forces and temperature as well as achievable material removal rate) Updated topics regarding process fluids for abrasive machining and fluid delivery

Completely revised and updated, this second edition of Fundamentals of Machining Processes: Conventional and Nonconventional Processes covers the fundamentals machining by cutting, abrasion, erosion, and combined processes. The new edition has been expanded with two additional chapters covering the concept of machinability and the roadmap for selecting machining processes that meet required design specification. See What’s New in the Second Edition: Explanation of the definition of the relative machinability index and how the machinability is judged Important factors affecting the machinability ratings Machinability ratings of common engineering materials by conventional and nonconventional methods. Factors to be considered when selecting a machining process that meets the design specifications, including part features, materials, product accuracy, surface texture, surface integrity, cost, environmental impacts, and the process and the machine selected capabilities Introduction to new Magnetic Field Assisted Finishing Processes Written by an expert with 37 years of experience in research and teaching machining and related topics, this covers machining processes that range from basic conventional metal cutting, abrasive machining to the most advanced nonconventional and micromachining processes. The author presents the principles and theories of material removal and applications for conventional and nonconventional machining processes, discusses the role of machining variables in the technological characteristics of each process, and provides treatment of current technologies in high speed machining and micromachining. The treatment of the different subjects has been developed from basic principles and does not require the knowledge of advanced mathematics as a prerequisite. A fundamental textbook for undergraduate students, this book contains machining data, solved examples, and review questions which are useful for students and manufacturing engineers.

Abrasive water jet machining was introduced to manufacturing ten years ago and has been increasingly used for treating hard-to-machine and multi-layered materials and as an alternative tool for milling, turning, drilling and polishing. This is the first comprehensive review of the technique, dealing with a broad range of issues including mixing and acceleration processes, material removal mechanisms, process optimization and fluid mechanics. Explanations are given as the book follows the development of an abrasive water jet machining process, from tool generation through to machining results, supervision and control. This methodical journey through the field is marked by drawings, graphs and tables, many of which are being published here for the first time. Though the book is written at an academic level, it focuses very much on practical applications, which reflects the authors' extensive involvement with both laboratory research and industrial practices.

This new edition draws upon the fundamentals of abrasive machining processes and the science of tribology to understand, predict, and improve abrasive machining processes. Each of the main elements of the abrasive machining system is looked at alongside the tribological factors that control the efficiency and quality of the processes described. The new edition has been updated to include a variety of industrial applications. Grinding and conditioning of grinding tools are dealt with in particular detail, and solutions are proposed for many of the most commonly experienced industrial problems, such as poor accuracy, poor surface quality, rapid tool wear, vibrations, workpiece burn, and high process costs. The entire book has been rewritten and restructured, with ten completely new chapters. Other new features include: - Extensive explanations of the main abrasive machining processes such as grinding (including reciprocating and creep-feed grinding, high-speed high-efficiency deep grinding, external and internal cylindrical grinding, and centerless grinding), honing, superfinishing, lapping, polishing, and finishing - Discussions of the new classes of abrasives, abrasive tools, and bonding materials - New case studies and troubleshooting on the most common grinding practices - New coverage on grinding tool conditioning, mechanical dressing, and nonmechanical dressing processes - Detailed explanations of the effects of process input parameters (such as cutting parameters, workpiece material and geometry, and abrasive tools) on process characteristics, workpiece quality, tool wear, and process parameters (such as cutting forces and temperature as well as achievable material removal rate) - Updated topics regarding process fluids for abrasive machining and fluid delivery

Presenting a comprehensive treatment of grinding theory and its practical utilization, this edition focuses on grinding as a machining process using bonded abrasive grinding wheels as the cutting medium. It provides a description of abrasives and bonded abrasive cutting tools.

This book draws upon the science of tribology to understand, predict and improve abrasive machining processes. Pulling together information on how abrasives work, the authors, who are renowned experts in abrasive technology, demonstrate how tribology can be applied as a tool to improve abrasive machining processes. Each of the main elements of the abrasive machining system are looked at, and the tribological factors that control the efficiency and quality of the processes are described. Since grinding is by far the most commonly employed abrasive machining process, it is dealt with in particular detail. Solutions are posed to many of the most commonly experienced industrial problems, such as poor accuracy, poor surface quality, rapid wheel wear, vibrations, work-piece burn and high process costs. This practical approach makes this book an essential tool for practicing engineers. Uses the science of tribology to improve understanding and of abrasive machining processes in order to increase performance, productivity and surface quality of final products A comprehensive reference on how abrasives work, covering kinematics, heat transfer, thermal stresses, molecular dynamics, fluids and the tribology of lubricants Authoritative and ground-breaking in its first edition, the 2nd edition includes 30% new and updated material, including new topics such as CMP (Chemical Mechanical Polishing) and precision machining for micro-and nano-scale applications

Fundamentals of Modern Manufacturing: Materials, Processes, and Systems is designed for a first course or two-course sequence in manufacturing at the junior or senior level in mechanical, industrial, and manufacturing engineering curricula. The distinctive and "modern" approach of the book emerges from its balanced coverage of the basic engineering materials, the inclusion of recent manufacturing processes and comprehensive coverage of electronics manufacturing technologies. The quantitative focus of the text is displayed in its emphasis on manufacturing science, greater use of mathematical models and end-of-chapter problems. This International Adaptation of the book offers revised and expanded coverage of topics and new sections on contemporary materials and processes. The new and updated examples and practice problems helps students gain solid foundational knowledge and the edition has been completely updated to use SI units.

Machining remains a hugely important process in modern engineering and manufacturing practice, and students need to be aware of the vast host of methods and technologies available to meet all sorts of precision and surface finish requirements. Fundamentals of Machining Processes: Conventional and Nonconventional Processes is the first textbook to collect all of the major methods into a single reference, from cutting and abrasive processes to erosion, hybrid, and micromachining processes. A Solid Foundation The text begins with an introduction to the various machining processes, followed by detailed discussions of cutting tool materials and geometry, mechanics of orthogonal cutting, the various factors affecting the economics of machining, and cutting methods for both flat and cylindrical surfaces. The author then shifts focus to high-speed machining and abrasive processes, including abrasive finishing and advanced processes such as ultrasonic and abrasive jet machining. A Firm Step Forward After laying a groundwork in the conventional processes, El-Hofy delves into modern machining topics. He explains electrochemical and thermal erosion techniques, combined machining processes, and the various micromachining techniques based on the previously discusses processes. Extensive worked examples, illustrations, and homework problems reinforce a practical understanding of the concepts. Reflecting the author's more than 30 years of industrial and teaching experience, Fundamentals of Machining Processes is a resource that students will carry with them well into their careers.

Principles of Laser Materials Processing Authoritative resource providing state-of-the-art coverage in the field of laser materials processing, supported with supplementary learning materials Principles of Laser Materials Processing goes over the most recent advancements and applications in laser materials processing, with the second edition providing a welcome update to the successful first edition through updated content on the important fields within laser materials processing. The text includes solved example problems and problem sets suitable for the readers’ further understanding of the technology explained. Split into three parts, the text first introduces basic concepts of lasers, including the characteristics of lasers and the design of their components, to aid readers in their initial understanding of the technology. The text then reviews the engineering concepts that are needed to analyze the different processes. Finally, it delves into the background of laser materials and provides a state-of-the-art compilation of material in the major application areas, such as laser cutting and drilling, welding, surface modification, and forming, among many others. It also presents information on laser safety to prepare the reader for working in the industry sector and provide practicing engineers the updates needed to work safely and effectively. In Principles of Laser Materials Processing, readers can expect to find specific information on: Laser generation principles, including basic atomic structure, atomic transitions, population distribution, absorption, and spontaneous emission Optical resonators, including standing waves in a rectangular cavity, planar resonators, beam modes, line selection, confocal resonators, and concentric resonators Laser pumping, including optical pumping, arc/flash lamp pumping, energy distribution in the active medium, and electrical pumping Broadening mechanisms, including line-shape functions, homogeneous broadening such as natural and collision, and inhomogeneous broadening Principles of Laser Materials Processing is highly suitable for senior undergraduate and graduate students studying laser processing, and non-traditional manufacturing processes; it is also aimed at researchers to provide additional information to be used in research projects that are to be undertaken within the technology field.