Modern Machining Technology: Advanced, Hybrid, Micro Machining and Super Finishing Technology

Front Matter
Copyright
Preface
Acknowledgment
Need of advanced machining technology
	Contents
	Chronological development of machining
	Utility of advanced machining technology
	References
Classification of advanced machining technology
	Contents
	Introduction
	Classifications of modern machining processes
	Selection of modern machining processes
	References
Machining processes utilizing mechanical energy
	Ultrasonic Machining (USM)
		Introduction
			Fundamentals of ultrasonic machining
			Need of ultrasonic machining
		Mechanism of material removal in USM
			Material removal mechanism in stationary USM
			Material removal mechanism in rotary USM
		Details of stationary ultrasonic machining system
			Tool vibration unit
			Workpiece holding unit
			Abrasive slurry supply unit
			Tool feeding and control unit
			Power supply unit
			Specification of ultrasonic machining setup
		Details of rotary ultrasonic machining system
			Tool vibration unit
			Data acquisition unit
			Coolant supply unit
		Influences of process parameters on performance criteria of stationary ultrasonic machining
			Influences of process parameters on material removal rate
			Influences of process parameters on overcut criteria
			Influences of process parameters on circularity error
		Influences of process parameters on performance criteria of rotary ultrasonic machining
			Influences of process parameters on material removal rate
			Influences of process parameters on surface roughness
			Influences of process parameters on cutting force
		Advantages and limitations of ultrasonic machining
			Stationary ultrasonic machining
			Rotary ultrasonic machining
		Applications of ultrasonic machining
			Stationary ultrasonic machining
			Rotary ultrasonic machining
		Advancement in ultrasonic machining technology
		References
	Abrasive Jet Machining (AJM)
		Introduction
			Fundamentals of abrasive jet machining
			Mechanism of material removal in AJM
				Modeling of material removal in AJM
		Details of AJM machining system
			Gas propulsion system
			Abrasive feeder and mixing chamber
			Machining chamber
			Nozzle
			Abrasives
		Influence of process parameters on performance criteria of AJM process
			Effect of abrasive flow rate and grain size and mixing ratio on MRR
			Effect of nozzle pressure on MRR
			Effect of stand-off distance on width of cut and MRR in AJM
		Advantages and limitations of abrasive jet machining processes
		Applications of abrasive jet machining processes
		Advancement in AJM technology
		References
	Water Jet Machining (WJM)
		Introduction
			Mechanisms of material removal
		Details of water jet machining system
		Effect of process parameters on machining criteria of WJM
		Advantages and limitations of water jet machining
			Advantages
			Limitations
		Applications of water jet machining
		Advancement in water jet machining technology
		References
	Ion Beam Machining (IBM)
		Introduction
			Basic functions of ion beam processing
			Material removal mechanism in ion beam machining
				Mathematical formulation on mechanism of ion beam machining
			Types of ion beam machining processes
		Focused ion beam (FIB) machining system setup
			Liquid metal ion sources (LMIS)
			Machining system setup
			Gas cluster ion beam (GCIB)
			GSIB processing setup
		Focused ion beam milling
		Influence of process parameters on performance criteria of IBM process
			Beam parameters
			Operation parameters
			Scan strategy
			FIB simulation software
		Advantages and limitations of ion beam machining process
		Applications of ion beam machining process
		Advancement in IBM
		3.5 Model Questions
			Ultrasonic machining (USM)
			Abrasive jet machining (AJM)
			Water jet machining (WJM)
			Ion beam machining (IBM)
		References
		Further reading
Machining processes utilizing thermal energy
	Introduction
	Introduction
	Mechanism of material removal
		Energy distribution
	EDM equipment
		EDM power supply
		Control system for EDM process
			Gap control by servo feed mechanism
		Dielectric system
			Types of dielectrics
			Flushing of dielectric
		Tool electrode
			Tool electrode materials
			Tool wear
			Fabrication and design aspects
	Modeling of EDM processes
		Material removal at single discharge in EDM
		Estimation of material removal and surface finish for RC circuit
		Surface finish
		Material removal for pulse generator circuit
		Generalized approaches for EDM modeling
	Influence of EDM parameters on machining characteristics
		Influence of polarity
	Machining accuracy and surface integrity
		Taper
		Overcut
		Surface integrity
	Wire Electro Discharge Machining (WEDM)
		Basic principle
			Features of WEDM
		Major components of WEDM systems
		Influence of WEDM process parameters
		Mathematical modeling for material removal rate (MRR) in WEDM
		Taper cutting system in WEDM
		Forces acting on the wire
		Finishing and accuracy
			Trim cutting features in WEDM
		Coated wire electrode
		Wire path strategy
			Wire tool vibration
				Methods for minimizing wire vibration
		Wire-lag phenomenon during machining
			Mathematical modeling of wire lag in WEDM
		Advancement in WEDM
		Applications of wire-cut EDM
	Electro discharge grinding
		Process mechanism
		Setup detail
		Types of EDG
		Influence of process parameters
	Advantages and limitations of various EDM processes
		Advantages
		Limitations
	Environmental impacts of EDM
		Protective measures
	Applications of EDM
	Advancement in EDM
		Advance power supply and control system
		Tool design and fabrication
		Dry EDM
		Alloying and coating with EDM
		Machining of nonconducting materials
	References
	Further reading
	Introduction
		Mechanism of material removal and machining rate in PAM
		Types of plasma arc machining system
	Details of plasma arc machining system setup
		Power supply unit
		Plasma gas supply unit
		Shielding gas supply unit
		Plasma torch
	Influence of process parameters on performance criteria of PAM process
	Advantages and limitations of plasma arc machining process
	Applications of plasma arc machining process
	Advancement in PAM technology
	References
	Introduction
		Types of lasers in machining applications
	Fundamental of laser generation
		Fundamentals of Nd: YAG laser generation
		Fundamentals of fiber laser generation
		Fundamentals of CO2 laser generation
		Fundamentals of excimer laser generation
		Fundamentals of diode laser generation
	Material removal mechanism in laser beam machining
	Laser beam machining systems details
		Laser generation and beam delivery unit
		Cooling unit
		Assist gas supply unit
		CNC controller for X-Y-Z axes movement
	Process parametric studies on performance criteria of LBM
		Laser drilling
		Laser cutting
		Laser grooving
		Laser turning
		Laser marking
	Advantages and limitations of laser beam machining processes
	Applications of laser beam machining processes
	Advancements of laser beam machining technology
	References
	Introduction
		Fundamental of electron beam generation
		Material removal mechanism in electron beam machining
	Electron beam machining system setup
	Theoretical consideration for EBM
		Current density
		Effects of aberrations on maximum current density
		Material removal
	Influence of process parameters on performance criteria of EBM processes
		Process parameters
		Process capabilities related to various performance criteria
	Advantages and limitations of electron beam machining processes
		Advantages
		Limitations
	Concise summary of EBM characteristics
	Applications of electron beam machining processes
		Drilling
		Perforation of thin shit
		Slotting
		Integrated circuit fabrication
	Advancements in EBM
	Model questions
		Electro discharge machining (EDM)
		Plasma arc machining (PAM)
		Laser beam machining (LBM)
		Electron beam machining (EBM)
	References
Machining processes utilizing chemical and electrochemical energy
	Introduction
	Working principle
	Process parameters of CM
		Parameters related to etchants
		Parameters related to masks
	Chemical blanking
	Chemical milling
	Photochemical machining
	Advantages and limitations of CM
	Applications of CM
	Advancement in chemical machining
	References
	Introduction
		Principles of electrolysis
		Working principle
			Polarization curves
			Overvoltage
	Kinematics and dynamics of ECM
	Effects of heat and bubble generation
	ECM equipment details
	Electrolyte flow paths and insulation
	Tool material and electrolytes
	Influence of ECM parameters on machining performances
	Surface integrity and accuracy
		Surface integrity
		Accuracy
	Tool design
		Tool design for known and mathematically defined machined surface by cosθ method
		Determination of the tool shape by finite element method
	Different variants of ECM
		Electrochemical drilling
		Electrochemical deburring
		Electrochemical milling
			Advantages of EC milling
			Challenges of EC milling
		Wire electrochemical machining (WECM)
		Electrochemical sawing
		Electrochemical grinding
		Electrochemical honing
		Electrochemical turning
	Environmental impacts of ECM
	Advantages and limitations of ECM
	Applications of ECM
	Advancement in ECM
	Model questions
		Chemical machining
		Electrochemical machining (ECM)
	References
	Further reading
Hybrid machining technology
	Introduction
	Need and basis of classification of HMP
	Electrochemical grinding
		Introduction
		Working principle of ECG
		ECG machining set-up details
		Material removal rate in ECG
		Analysis of the process parametric influences on metal removal rate (MRR) in ECG
		Process capabilities of ECG
		Advantages and limitations
		Applications of ECG
		Advancements in ECG
	Electrochemical arc machining
		Introduction
		Working principle of ECAM
		ECAM machining set-up details
		Material removal rate in ECAM
			Case (a): Sinusoidal pulsed supply voltage waveform with tool vibration
			Case (b): A Rectangular pulsed supply voltage and vibration with the cathodic tool
			Case (a)l: Sinusoidal pulsed voltage and with vibrational motion to the tool
			Case (b): Rectangular pulsed supply voltage waveform between the electrodes and sinusoidal vibration motion with the cathod ...
				Identification of the partitioning effects of ECD and EDE phases in ECAM
		Influences of ECAM process parameters on machining characteristics
		Process capabilities of ECAM
		Advantages and limitations
		Applications
		Advancements in ECAM
	Electrochemical discharge machining
		Introduction
		Working principle of ECDM
			Electrochemical reaction mechanism in ECDM
			Reaction at cathode (or tool)
			Reaction at anode (auxiliary electrode)
			(a) Electrical discharge phenomena in ECDM
			(b) Thermal spalling phenomena in ECDM
			(c) Mechanism of tool wear in ECDM
		ECDM machining set-up details
		Material removal rate in ECDM
		Influences of ECDM process parameters on machining characteristics
		(b) Analysis of influences of process parameters on accuracy, i.e., overcut and machining depth criteria in ECDM
	Process capabilities of ECDM
	Advantages and limitations
	Applications
	Advancements in ECDM
	Abrasive assisted advanced machining
		Introduction
		Abrasive water jet machining
			Mechanism of material removal in AWJM
			Details of the AWJM setup
			Process parametric studies on machining performance criteria of AWJM
			Advantages of AWJM
			Limitations of AWJM
			Application of AWJM
		Abrasive assisted EDM
		Abrasive assisted ECM
	Vibration assisted advanced machining
		Introduction
		Vibration assisted mechanical machining
		Vibration assisted EDM
		Vibration assisted ECM
		Vibration assisted LBM
	Laser assisted advanced machining
		Introduction
		Laser assisted mechanical machining (LAMM)
			Laser assisted turning
			Laser assisted milling
			Laser assisted ceramic machining
		Laser assisted advanced machining (LAAM)
			Laser assisted WJM
			Laser assisted EDM
			Laser assisted chemical and electrochemical machining
			Laser-assisted etching (LAE)
	Advantages and limitations of hybrid machining processes
	Advancements in hybrid machining processes
	Model questions
	References
Micromachining processes
	Introduction
	Need and basic of classification
		Mechanical micromachining
		Thermal micromachining
		Chemical and electrochemical micromachining
	Conditions for micromachining
	Micro ultrasonic machining (micro-USM)
		Introduction
		Basic mechanism
		Setup details
		Comparisons of USM and micro-USM
		Influence of process parameters
		Advancements and challenges
		Applications
	Micro electro discharge machining (micro-EDM)
		Introduction
		Basic mechanism
		Setup details
		Comparisons of EDM and micro-EDM
			Types of micro-EDM
		Influences of process parameters
		Advancement and challenges
		Applications
	Micro laser beam machining (micro-LBM)
		Introduction
		Basic mechanism
		Setup details
		Comparisons of LBM and micro-LBM
		Influence of process parameters
		Advantages and challenges
		Applications
	Electrochemical micromachining (EMM)
		Introduction
		Basic mechanism
		Setup details
		Comparisons of ECM and EMM
		Influence of process parameters
		Advantages and challenges
		Applications
	Hybrid micromachining
		Introduction
		Micro-EDM and micro ECM hybridization
		Micro-ECM and LBM hybridization
	Sequential micromachining (SMM) processes
		Introduction
		Basic concept and mechanism
		Development of different sequential micromachining strategies
		Process capabilities of SMM
		Advantages and challenges
		Applications
	Model questions
	References
Advanced finishing processes
	Introduction
	Introduction
	Basic working principle
	Setup details
	Influence of process parameters
	Advantages, disadvantages and challenges
	Applications
	References
	Introduction
	Basic principle of CMP process
	CMP setup details
	Influence of process parameters of CMP
	Advantages and limitations
	Applications
	References
	Introduction
	Basic working principle
	Setup details
	Influence of process parameters
	Advantages
	Applications
	References
	Introduction
	Basic working principle
	Setup details
	Influence of process parameters
	Advantages
	Applications
	References
	Introduction
	Basic principle of MRF process
	Setup details
	Influence of process parameters
	Advantages and challenges
	Applications
	References
	Introduction
	Basic working principle
	Setup details
	Influence of process parameters
	Advantages
	Applications
	Model questions
		Abrasive flow finishing (AFF)
		Chemical mechanical polishing (CMP)
		Elastic emission machining (EEM)
		Magnetic abrasive finishing (MAF)
		Magnetorheological finishing (MRF)
		Plasma assisted polishing (PAP)
		Advanced finishing processes
	References
Index
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