The scientific goal of the present work was to model the workpiece material behavior of steels in the metal cutting process depending on the occurring thermo-mechanical loads. The results of this work shall make a significant contribution to the predictive process design of the cutting process by means of Finite Element (FE) simulations for the virtual representation of the reality in the sense of the digital twin. To achieve the objective, extensive empirical examinations were conducted in a first step, which included conventional material scientific and orthogonal cutting tests. This enabled the establishment of a database of the workpiece response with increasing thermo-mechanical loads. During the orthogonal cutting examinations, integral and locally resolved process results were measured, which were used as calibration and validation variables in the modeling of the workpiece material behavior. By extending an established friction test bench with a workpiece pre-heating system, the friction conditions between tool and workpiece could be investigated under conditions equivalent to the cutting process. Based on the experimental results, a friction model was derived, in which the observed effects of thermal softening and the localized adhesion-induced increase in the apparent friction coefficient were superposed. A phenomenological material model was developed to describe the workpiece material behavior in the cutting process. The formulation of the material mode was developed based on empirical examinations as well as results from the state of the art. The material model was implemented in an FE-chip formation simulation using a subroutine. A hybrid optimization algorithm was developed to inversely determine the material model parameters. By means of the optimization algorithm, the material model parameters could be systematically determined inversely, taking the experimentally determined process observables into account. An automated procedure linked to a user interface lowered the entry hurdle for industrial companies and unexperienced users of FE-simulations and reduced the computational effort for the inverse parameter determination to about 10 days of computational execution time. The quality of the developed models and the determined model parameters were further verified by a final deduction step using the industrial example of face turning.

Written by authorities in the subject, this book provides a complete treatment of metal forming and machining by using the computational techniques FEM, fuzzy set theory and neural networks as modelling tools. The algorithms and solved examples included make this book of value to postgraduates, senior undergraduates, and lecturers and researchers in these fields. Research and development engineers and consultants for the manufacturing industry will also find it of use.

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

The Army Materials and Mechanics Research Center in coopera tion with the Materials Science Group of the Department of Chemical Engineering and Materials Science of Syracuse University has been conducting the Annual Sagamore Army Materials Research Conference since 1954. The specific purpose of these conferences has been to bring together scientists and engineers from academic institutions, industry, and government who are uniquely qualified to explore in depth a subject of importance to the Department of Defense, the Army, and the scientific community. The proceedings of this conference, entitled MATERIAL BEHAVIOR UNDER HIGH STRESS AND ULTRAHIGH LOADING RATES, will be published in two parts. The topics covered in the present volume include dynamic plasticity, adiabatic shear/localized deformation, and dynamic fracture mechanics. Papers dealing with ordnance applica tions, projectile launch environment, and recent work-in-progress will appear as an AMMRC Technical Report and will have more limited distribution in accordance with recent Army guidelines. The Conference Chairmen are particularly grateful to the members of the Program Committee. We wish also to acknowledge the assistance of Mr. Charles Polley of the Army Materials and Mechanics Research Center, Mr. Robert Sell, Ms. Helen Brown DeMascio, and Ms. Mary Ann Holmquist of Syracuse University throughout the con ference planning stages and the publication of the text. The continued active interest in and support of these confer ences by Dr. E. Wright and Col. George Sibert, Direct and Deputy Director/Commander, respectively, of the Army Materials and Mechan ics Research Center, is appreciated.

Metal Cutting is a guide that discusses the process of metal cutting and its different techniques. The book first gives a short history and introduction to metal cutting, and then discusses the operations and terminologies used in metal cutting; the essential features of metal cutting; and the forces involved. The use of heat, the cutting tool materials, the machinability of different metals and alloys, and the use of coolants and lubricants in metal-cutting machines are also explained. The text is recommended for metalworkers and engineers, especially those who are new to the industry, as this book serves as a handy reference for this craft.

Selected, peer reviewed papers from the 12th Conference on Machining & Advanced Manufacturing Technology, July 24- 27, 2013, Xiamen, China

Mechanics of Materials in Modern Manufacturing Methods and Processing Techniques provides a detailed overview of the latest developments in the mechanics of modern metal forming manufacturing. Focused on mechanics as opposed to process, it looks at the mechanical behavior of materials exposed to loading and environmental conditions related to modern manufacturing processes, covering deformation as well as damage and fracture processes. The book progresses from forming to machining and surface-treatment processes, and concludes with a series of chapters looking at recent and emerging technologies. Other topics covered include simulations in autofrettage processes, modeling strategies related to cutting simulations, residual stress caused by high thermomechanical gradients and pultrusion, as well as the mechanics of the curing process, forging, and cold spraying, among others. Some non-metallic materials, such as ceramics and composites, are covered as well. - Synthesizes the latest research in the mechanics of modern metal forming processes - Suggests theoretical models and numerical codes to predict mechanical responses - Covers mechanics of shot peening, pultrusion, hydroforming, magnetic pulse forming - Considers applicability of different materials and processes for optimum performance

Modeling and machining are two terms closely related. The benefits of the application of modeling on machining are well known. The advances in technology call for the use of more sophisticated machining methods for the production of high-end components. In turn, more complex, more suitable, and reliable modeling methods are required. This book pertains to machining and modeling, but focuses on the special aspects of both. Many researchers in academia and industry, who are looking for ways to refine their work, make it more detailed, increase their accuracy and reliability, or implement new features, will gain access to knowledge in this book that is very scare to find elsewhere.

The broaching process remains an essential machining process when manufacturing fir tree slots in turbine disks for aircraft engines. The cost- and time-intensive experiment-based approach restricts the application of alternative cutting tool materials when broaching nickel-based alloys. Given the accuracy and computation time, the developed model-based multiscale approach presents great advantages in prediction of the broaching process and thus can accelerate the development process.