Modern Manufacturing Processes

Provides an in-depth understanding of the fundamentals of a wide range of state-of-the-art materials manufacturing processes Modern manufacturing is at the core of industrial production from base materials to semi-finished goods and final products. Over the last decade, a variety of innovative methods have been developed that allow for manufacturing processes that are more versatile, less energy-consuming, and more environmentally friendly. This book provides readers with everything they need to know about the many manufacturing processes of today. Presented in three parts, Modern Manufacturing Processes starts by covering advanced manufacturing forming processes such as sheet forming, powder forming, and injection molding. The second part deals with thermal and energy-assisted manufacturing processes, including warm and hot hydrostamping. It also covers high speed forming (electromagnetic, electrohydraulic, and explosive forming). The third part reviews advanced material removal process like advanced grinding, electro-discharge machining, micro milling, and laser machining. It also looks at high speed and hard machining and examines advances in material modeling for manufacturing analysis and simulation. Offers a comprehensive overview of advanced materials manufacturing processes  Provides practice-oriented information to help readers find the right manufacturing methods for the intended applications  Highly relevant for material scientists and engineers in industry Modern Manufacturing Processes is an ideal book for practitioners and researchers in materials and mechanical engineering. 

Table of Contents:
Foreword xvii List of Contributors xix Part I Advanced Forming Processes 1 1 Advances in Stamping 3 Ilyas Kacar and Fahrettin Ozturk 1.1 Introduction 3 References 13 2 Hydroforming 15 C Hartl 2.1 Introduction 15 2.2 Fundamentals 16 2.3 Process Development and Design 33 2.4 Hydroforming Systems 37 2.5 Concluding Remarks 39 References 40 3 Incremental Sheet Forming 47 Rogelio Perez‐Santiago, Isabel Bagudanch, and Maria Luisa Garcia‐Romeu 3.1 Incremental Sheet Forming: General Overview 47 3.2 ISF Variants 49 3.3 Process Cycle 51 3.4 Materials 52 3.5 Formability in ISF 52 3.6 ISF Process Parameters 55 3.7 Accuracy 55 3.8 Simulation 57 3.9 Future Trends in ISF 58 3.10 Case Study 59 3.11 Concluding Remarks 59 References 60 4 Powder Forming 65 Rahmi Unal 4.1 Introduction 65 4.2 Reasons for Using PM Route 67 4.3 Powder Production 69 4.4 Consolidation Techniques 73 4.5 Sintering 79 4.6 Powder Injection Molding (PIM) 82 4.7 Summary and Future Work 84 References 85 5 Injection Molding at Multiscales 89 Danyang Zhao, Minjie Wang, and Donggang Yao 5.1 Introduction 89 5.2 Overview of Injection Molding 91 5.3 Injection Molding of Precision Parts 105 5.4 Injection Molding of Thin Wall Parts 109 5.5 Injection Molding of Microstructured Parts 116 5.6 Injection Molding of Microparts 124 5.7 Simulation of Injection Molding 127 5.8 Summary and Outlook 131 References 132 6 Manufacturing Techniques of Bulk Metallic Glasses 137 Mustafa Bakkal, Umut Karaguzel, and Ali T. Kuzu 6.1 Introduction 137 6.2 Mechanical Properties and Usage of Bulk Metallic Glasses 139 6.3 Rapid Quenching Methods 140 6.4 Water‐Quenching Method 141 6.5 Arc Melting Drop/Suction Casting Method 142 6.6 High‐Pressure Die Casting Method 143 6.7 Copper Mold Casting Method 144 6.8 Cap Casting Method 144 6.9 Centrifugal Casting Method 145 6.10 Metal Foaming Method 146 6.11 Concluding Remarks 147 References 147 7 Micromanufacturing 149 Omer N. Cora and Muammer Koc 7.1 Introduction 149 7.2 Classification of Micromanufacturing Processes 150 7.3 Micromanufacturing Processes 154 References 179 Part II Thermal and Energy‐assisted Manufacturing Processes 185 8 Warm Stamping 187 Fahrettin Ozturk , Serkan Toros, and Ilyas Kacar 8.1 What is Stamping? 187 8.2 Benefits and Usage Areas of Warm Stamping 187 8.3 Warm Stamping and Recent Developments 188 8.4 Effects of Temperature on Strain Hardening for Warm Stamping 194 8.5 Interrelation of Temperature and Strain Rate 196 8.6 Effect of Temperature and Deformation on Elasticity Modulus 198 8.7 Effect of Temperature on Springback 201 8.8 Effect of Temperature on Forming Limit Diagrams (FLD) 204 8.9 Analyze Techniques on Formability at Warm Stamping 205 8.10 The Effects of Lubrication 215 8.11 Future Directions 215 References 216 9 Warm Hydroforming 219 Muammer Koc, Omer N. Cora, Huseyin S. Halkacı, and Mevlut Turkoz 9.1 Introduction 219 9.2 Warm Sheet Hydroforming 220 9.3 Warm Hydromechanical Deep Drawing 230 9.4 Warm Tube Hydroforming 231 References 237 10 Hot Stamping 239 Fahrettin Ozturk , Ilyas Kacar, and Muammer Koc 10.1 Introduction 239 10.2 Process Description and Motivation 240 10.3 Why Hot Stamping? 241 10.4 Automotive Parts by Hot Stamping and Potentials 241 10.5 Advantages and Disadvantages 243 10.6 Process Description and Methods 245 10.7 Cooling for Hot Stamping 254 10.8 Process Control 255 10.9 Modeling and Analysis 255 10.10 Design and Optimization in Hot Stamping 256 10.11 FEA in Hot Stamping 257 10.12 Research and Development Trends and Needs 258 References 262 11 High‐Speed Forming (Electromagnetic, Electrohydraulic, and Explosive Forming) 265 Brad Kinsey and Yannis Korkolis 11.1 Introduction 265 11.2 Electromagnetic Forming and Magnetic Pulsed Welding 267 11.3 Electrohydraulic Forming 274 11.4 Explosive Forming 279 11.5 Emerging Technologies 282 11.6 Metrology and Measurements 284 11.7 Material Characterization 286 11.8 Modeling of High‐Speed Forming Processes 288 11.9 Summary and Future Work 291 References 292 Part III Advanced Material Removal Processes 295 12 High‐Speed Machining 297 Elisa Vazquez and Guillem Quintana 12.1 High‐Speed Machining Overview 297 12.2 High‐Speed Machining Processes and Capabilities 298 12.3 Machine Tools for High‐Speed Machining 298 12.4 Tools for High‐Speed Machining 300 12.5 High‐Speed Machining Applications and Future Trends 305 References 306 13 Hard Machining 309 Durul Ulutan and Tuğrul Ozel 13.1 Introduction 309 13.2 Mechanics of Hard Machining 312 13.3 Cutting Tools 313 13.4 Surface Quality and Integrity 316 13.5 Summary and Conclusions 320 References 320 14 Advances in Material Modeling for Manufacturing Analysis and Simulation (Deformation and Cutting Processes) 323 Elisabetta Ceretti, Claudio Giardini, and Antonio Fiorentino 14.1 Introduction on Material Characterization and Modeling 323 14.2 Material Models and Applications 324 14.3 Failure Models 327 14.4 Modeling of Contact, Friction, and Wear 331 References 347 15 Advanced Grinding 351 Taghi Tawakoli and Amir Daneshi 15.1 Introduction 351 15.2 Grinding Wheels 351 15.3 Bond Materials 353 15.4 Grinding Wheel Conditioning 354 15.5 Grinding Force and Energy 363 15.6 Thermal Damages in Grinding 363 15.7 Environmentally Friendly Grinding 364 15.8 High‐efficiency Deep Grinding (HEDG) 367 15.9 Ultrasonic‐Assisted Grinding (UAG) 367 15.10 Ultrasonic‐Assisted Dressing 371 References 373 16 Electro‐Discharge Machining (EDM) 377 Muhammad P. Jahan 16.1 Introduction 377 16.2 Principle of the EDM Process 378 16.3 EDM System Components 379 16.4 Analysis of the Pulses Used in the EDM Process 383 16.5 Brief Overview of the EDM Parameters 384 16.6 EDM Variants: Working Principles and Application Examples 385 16.7 Examples of Research Advances in EDM and Micro‐EDM 393 16.8 Research Focus Toward Micro‐ and Nano‐EDM 402 16.9 Summary 403 References 404 17 MicroMilling Operations 411 Simon S. Park, Martin B.G. Jun, and Gerardo Garcia 17.1 Introduction 411 17.2 Machine Tools for Micromilling 413 17.3 Micromilling Forces 420 17.4 Tool Tip Dynamics 427 17.5 Summary 430 References 431 18 Laser Machining 427 Dani Teixidor, Ines Ferrer, Luis Criales, and Tuğrul Ozel 18.1 Introduction 435 18.2 Laser–Material Interaction 437 18.3 Laser Processing of Materials 438 18.4 Laser‐Processing Parameters 442 18.5 Laser Drilling 445 18.6 Laser Cutting 448 18.7 Laser Milling 450 18.8 Concluding Remarks 452 References 453 19 Laser‐assisted Machining Operations 459 Eneko Ukar, Ivan Tabernero, Silvia Martinez, Aitzol Lamikiz, and Asier Fernandez 19.1 Introduction 459 19.2 Heat‐assisted Processes 460 19.3 Analysis of LAM Processes 470 19.4 Laser‐assisted Applications 474 19.5 Conclusions 477 References 478 20 Selective Laser Sintering 481 Jordi Delgado, Lidia Sereno, Karla Monroy, and Joaquim Ciurana 20.1 General Overview 481 20.2 Mechanisms 483 20.3 Process Parameters 486 20.4 Materials 490 20.5 Capabilities and Limitations 494 References 496 Index 501

About the Author :
MUAMMER KOÇ, PHD, is Professor and Program Coordinator of Sustainable Development Division at College of Science and Engineering, Hamid bin Khalifa University, Qatar. His research interests include nano/micro-scale engineered surfaces, manufacturing system modeling, lightweight materials, product design and development, sustainable energy, and social and organizational efficiency. TUĞRUL ÖZEL, PHD, is the Director of Manufacturing Automation Research Laboratory and Associate Professor in the Department of Industrial and Systems Engineering at Rutgers University, USA. His teaching and research interests include manufacturing processes, modeling and simulation, surface integrity, precision machining, metal additive manufacturing, and laser based materials processing.