Materials Forming, Machining and Post Processing (eBook)

Kapil Gupta (Herausgeber)

eBook Download: PDF

2019
VIII, 268 Seiten
Springer International Publishing (Verlag)
978-3-030-18854-2 (ISBN)

Infos

This book provides a detailed understanding of various forming, machining, and post processing techniques. Working principle, process mechanism, salient features and latest developments are primarily focused. It presents some basic and specialized processes to produce quality engineered parts. This book also incorporates some investigations on modelling, simulation and optimization of the aforementioned processes to improve quality and performance, productivity, and sustainability. 

Kapil Gupta is a Senior Lecturer in the Dept. of Mechanical and Industrial Engineering Technology at the University of Johannesburg. Advanced machining processes, sustainable manufacturing, precision engineering and gear technology are the areas of his interest and specialization. Currently, he is doing research in advanced/modern machining,  sustainable manufacturing and gear engineering.

Inhalt

Preface 6
Contents 8
Fundamentals in Sheet and Tube Forming: Material Characterization, Conventional and Novel Processes and Involved Mechanics 10
1 Materials Characterization of Sheet and Tube Material 12
1.1 Tensile Test for Sheet Metal 12
1.2 Tensile Test for Tube Metal 15
1.3 Material Input in Finite Element Method 16
2 Sheet Forming Processes 17
2.1 Dome Test 18
2.2 Forming Limit Diagram 19
2.3 Biaxial Test 20
2.4 Limiting Drawing Ratio Test (Deep Drawing Test) 21
2.5 Hole Expansion Test 25
3 Sheet Forming Processes—Conventional Techniques 27
3.1 Shearing 27
3.2 Bending 28
3.3 Stamping 29
4 Sheet Forming Processes—Novel Techniques 30
4.1 Hydroforming 30
4.2 Rubber Forming 32
4.3 Tailor Welded Blanks 33
4.4 Roll Forming 34
4.5 Incremental Forming 35
4.6 Electric Assisted Forming 35
4.7 Explosive Forming 36
4.8 Electro Hydraulic Forming 37
4.9 Electromagnetic Forming 38
5 Tube Forming Processes 38
5.1 Tube Flaring 39
5.2 Rotational Flaring 39
5.3 Tube Hydroforging 40
5.4 Reuleaux Forming 41
6 Mechanics in Sheet Metal Forming 41
6.1 Equibiaxial Tension 43
6.2 Plane Strain 43
6.3 Uniaxial Tension 44
6.4 Pure Shear 44
6.5 Uniaxial Compression 44
6.6 Through Thickness Pressure 44
6.7 Through Thickness Shear 45
7 Common Challenges in Sheet Metal Forming 45
7.1 Springback 45
7.2 Buckling and Wrinkling 46
7.3 Fracture 46
References 47
Analysis and Optimization of Metal Injection Moulding Process 49
1 Introduction 50
2 Manufacturing Process 52
2.1 Powders Particle Size and Shape for MIM 52
3 Materials and Methodology for MIM Process 53
4 Results and Discussion 65
4.1 Statistical Taguchi Method 65
4.2 Grey Relational Analysis (GRA) and Principal Component Analysis (PCA) 71
4.3 Summary Results of Optimization 77
5 Conclusions 80
References 81
On Friction-Stir Welding of 3D Printed Thermoplastics 83
1 Introduction 83
2 Research Advances in FSW 85
3 FSW and 3D Printing 88
3.1 Tool Design 90
3.2 Friction Stir Welding of 3D Printed Acrylonitrile Butadiene Styrene: Case Study 92
4 Conclusions 96
References 97
4D Printing 100
1 Introduction 100
1.1 3D Printing 101
2 Advancement in 3D Printing 101
2.1 4D Printing: Reinventing Manufacturing 102
3 Biomimetic 104
4 4D Printing Materials 105
4.1 Shape Memory Polymers (SMPs) 108
4.2 Thermoset Shape Memory Polymers 109
4.3 Shape Memory Thermoplastic Polymers 109
4.4 Self-healing Hydrogel Materials 110
5 Applications 110
6 SWOT Analysis 111
7 Conclusions 112
8 Future Scope 113
References 114
Non-conventional Micro-machining Processes 115
1 Introduction 116
2 Micro Machining Process 117
2.1 Conventional Micro Machining Processes 117
2.2 Need for Non-conventional Micro Machining 118
2.3 Classification of Non-conventional Micro Machining Processes 118
3 Mechanical Micro-machining Processes 119
3.1 Ultrasonic Micro Machining 120
3.2 Abrasive Jet Micro Machining 121
3.3 Abrasive Water Jet Micro Machining 123
4 Thermal Micro-machining Processes 125
4.1 Laser Beam Micro Machining 125
4.2 Electric Discharge Micro Machining 127
5 Chemical Micro-machining Processes 128
5.1 Chemical Micro Milling Process 128
5.2 Electro Chemical Micro Machining 129
6 Hybrid Micro-machining Processes 131
6.1 Electrochemical Grinding (ECG) 132
6.2 Electrochemical Discharge Machining 133
6.3 Abrasive Assisted Micromachining (AAMMP Process) 136
6.4 Ultrasonic Assisted Micromachining 137
7 Conclusions 141
References 141
RETRACTED CHAPTER: Investigation on Spark Erosion Machining Induced Surface Integrity of Super-Alloys 146
1 Introduction 147
2 Spark-Erosion Process 149
2.1 Wire Electrical Discharge Machining (Wedm) 149
2.2 Rough Cut and Trim Cutting Operation 151
3 Experimentations 152
4 Results Discussion 154
4.1 Cutting Speed (CS) 155
4.2 Surface Roughness (SR) 155
4.3 Micro Hardness 157
5 Recast Layer 158
6 Conclusions 161
References 161
Role of Eco-friendly Cutting Fluids and Cooling Techniques in Machining 163
1 Introduction 163
2 Cutting Fluids 166
2.1 Functions of Cutting Fluids 166
2.2 Classification of Conventional Cutting Fluids 167
2.3 Ecological Aspects of Conventional Cutting Fluids 169
2.4 Eco-friendly Cutting Fluids 170
2.5 Cutting Fluid Application Techniques During Machining 171
2.6 Role of Eco-friendly Cutting Fluids and Cooling Techniques on Machining Performance 176
3 Sustainable Machining for Future 180
4 Conclusion 180
References 181
Titanium Machining Using Indigenously Developed Sustainable Cryogenic Machining Facility 186
1 Introduction 187
2 Literature Review 188
3 Methodology to Design Cryogenic Fluid Delivery Setup 193
3.1 Selection of Delivery Pressure and Flow Rate of Cryogenic Fluid 194
3.2 Selection of Delivery Nozzle at the Outlet 194
3.3 Designing of the Cryogenic Fluid Delivery Transfer Line 194
4 Economic Aspect of Cryogenic Machining 195
5 Experimental Study on Cryogenic Machining of Ti-6Al-4V 196
5.1 Research Methodology 196
6 Results and Discussion 198
6.1 Surface Roughness 198
6.2 Resultant Forces 201
6.3 Power Consumption 202
7 Conclusions 206
References 206
Advanced Laser Based Surface Treatment Techniques to Improve the Quality of the Products 209
1 Introduction 210
1.1 Laser Glazing 210
1.2 Laser Shock Peening 211
1.3 Laser Annealing 215
2 Laser Material Interaction 216
3 Numerical Modelling 217
4 Experimental Procedure 222
4.1 Laser Glazing 222
4.2 Laser Shock Peening 223
4.3 Laser Annealing 224
5 Results and Discussion 225
5.1 Validation of Numerical Modelling 225
5.2 Surface Morphology 227
5.3 Mechanical Properties 228
6 Conclusion 229
References 229
LASER Cladding—A Post Processing Technique for Coating, Repair and Re-manufacturing 232
1 History of the Process 233
2 Principles of the Process Operation 234
3 Applicability of the Process 241
4 Materials Utilized in the Cladding Process 243
5 Advantages and Limitations 244
6 Recent Developments in LASER Cladding 246
References 249
Electrochemical Behaviour and Surface Studies on Austenitic Stainless Steel and Nickel-Based Superalloy Dissimilar Weld Joints 251
1 Introduction 252
2 Materials and Welding Process 253
2.1 Welding Materials 253
2.2 Laser Beam Welding 254
2.3 Electron Beam Welding 254
2.4 Selection of EBW and Laser Welding Process 255
2.5 Welding of Dissimilar Materials 257
3 Results and Discussion 258
4 Conclusions 263
References 265
Retraction Note to: Investigation on Spark Erosion Machining Induced Surface Integrity of Super-Alloys 267
Retraction Note to: Chapter “Investigation on Spark Erosion Machining Induced Surface Integrity of Super-Alloys” in: K. Gupta (ed.), Materials Forming, Machining and Post Processing, Materials Forming, Machining and Tribology, https://doi.org/10.1007/978-3-030-18854-26 267
Index 268

Produkt-Details

• Erscheint lt. Verlag: 27.6.2019
• Reihe/Serie: Materials Forming, Machining and Tribology
• Reihe/Serie: Materials Forming, Machining and Tribology
• Zusatzinfo: VIII, 268 p. 170 illus., 88 illus. in color.
• Sprache: englisch
• Themenwelt: Technik ► Maschinenbau
• Schlagworte: Bulk forming • electric discharge coating • hybrid finishing • hybrid machining • Incremental Forming • mechanical hardening • powder forming • sheet metal forming
• ISBN-10: 3-030-18854-X / 303018854X
• ISBN-13: 978-3-030-18854-2 / 9783030188542