Hybrid Machining Processes

Hybrid Machining: Theory, Methods, and Case Studies covers the scientific fundamentals, techniques, applications and real-world descriptions of emerging hybrid machining technology. This field is advancing rapidly in industrial and academic contexts, creating a great need for the fundamental and technical guidance that this book provides. The book includes discussions of basic concepts, process design principles, standard hybrid machining processes, multi-scale modeling approaches, design, on-machine metrology and work handling systems. Readers interested in manufacturing systems, product design or machining technology will find this one-stop guide to hybrid machining the ideal reference. Includes tables of recommended processing parameters for key engineering materials/products for each hybrid machining process Provides case studies covering real industrial applications Explains how to use multiscale modeling for hybrid machining

This book describes various hybrid machining and finishing processes. It gives a critical review of the past work based on them as well as the current trends and research directions. For each hybrid machining process presented, the authors list the method of material removal, machining system, process variables and applications. This book provides a deep understanding of the need, application and mechanism of hybrid machining processes.

This book explores, in a systematic way, both conventional and unconventional material shaping processes with various modes of hybridization in relation to theory, modelling and industrial potential. The demand for high productivity and high accuracy in manufacturing is continuously increasing, based on improvement and optimization strategies. Hybridization of manufacturing processes will play a crucial role and will be of a key importance in achieving environmental and economical sustainability. Structured in three parts, Hybrid Manufacturing Processes summarizes the state-of-the art hybrid manufacturing processes based on available literature sources and production reports. The book begins by providing information on the physical fundamentals of the removal and non-removal processes in macro-, micro and nanoscales. It then follows with an overview of the possible ways of hybridization and the effects on the enhancement of process performance, before concluding with a summary of production outputs related to surface integrity, specifically with respect to difficult-to-machine materials. Considering the applications of different sources of hybridization including mechanical, thermal and chemical interactions or their combinations, this book will be of interest to a range of researchers and practicing engineers within the field of manufacturing.

Today’s stringent design requirements and difficult-to-machine materials such as tough super alloys, ceramics, and composites, have made traditional machining processes costly and obsolete. As a result, manufacturers and machine design engineers are turning to advance machining processes. These machining processes utilizes electrical, chemical, and optimal sources of energy to bind, form and cut materials. El-Hofy rigorously explains how each of these advanced machining process work, their machining system components, process variables and industrial applications, making this book the perfect guide for anyone designing, researching or converting to a more advance machining process.

This new book covers process optimization and process capability for hybrid NCMP (nonconventional machining process), and combines NCMP and conventional machining removal processes for various hybridized processes. This book is focused on understanding the basic mechanism of some of the NCMPs for their possible hybridization. This book can be used for the development of a basic framework on hybridization for the selected NCMP. The framework is further strengthened by case studies included in this book. The concept of macro-modeling for NCMP and the framework for the development of industrial standards have been outlined. This book is of interest to researchers and graduate students working in the field of hybrid NCMP, especially for the development of novel processes. Field engineers of NCMP may also use it for further process development. Features: Provides a detailed description of mechanism for different NCMPs for possible hybridization. Includes a case study on mechanism of processes. Offers a systematic approach for understanding NCMP. Covers the issues of process optimization and process capability for hybrid NCMP.

Advanced Machining Processes of Metallic Materials: Theory, Modelling and Applications, Second Edition, explores the metal cutting processes with regard to theory and industrial practice. Structured into three parts, the first section provides information on the fundamentals of machining, while the second and third parts include an overview of the effects of the theoretical and experimental considerations in high-level machining technology and a summary of production outputs related to part quality. In particular, topics discussed include: modern tool materials, mechanical, thermal and tribological aspects of machining, computer simulation of various process phenomena, chip control, monitoring of the cutting state, progressive and hybrid machining operations, as well as practical ways for improving machinability and generation and modeling of surface integrity. This new edition addresses the present state and future development of machining technologies, and includes expanded coverage on machining operations, such as turning, milling, drilling, and broaching, as well as a new chapter on sustainable machining processes. In addition, the book provides a comprehensive description of metal cutting theory and experimental and modeling techniques, along with basic machining processes and their effective use in a wide range of manufacturing applications. The research covered here has contributed to a more generalized vision of machining technology, including not only traditional manufacturing tasks, but also potential (emerging) new applications, such as micro and nanotechnology. Includes new case studies illuminate experimental methods and outputs from different sectors of the manufacturing industry Presents metal cutting processes that would be applicable for various technical, engineering, and scientific levels Includes an updated knowledge of standards, cutting tool materials and tools, new machining technologies, relevant machinability records, optimization techniques, and surface integrity

It is always hard to set manufacturing systems to produce large quantities of standardized parts. Controlling these mass production lines needs deep knowledge, hard experience, and the required related tools as well. The use of modern methods and techniques to produce a large quantity of products within productive manufacturing processes provides improvements in manufacturing costs and product quality. In order to serve these purposes, this book aims to reflect on the advanced manufacturing systems of different alloys in production with related components and automation technologies. Additionally, it focuses on mass production processes designed according to Industry 4.0 considering different kinds of quality and improvement works in mass production systems for high productive and sustainable manufacturing. This book may be interesting to researchers, industrial employees, or any other partners who work for better quality manufacturing at any stage of the mass production processes.

Written by an expert with over 40 years of experience in research and teaching machining and related topics, this new edition textbook presents the principles and theories of material removal and applications for conventional, nonconventional and hybrid machining processes. The new edition is ideal for undergraduate students in production, materials, industrial, mechatronics, marine, mechanical, and manufacturing engineering programs, and also useful for graduate programs related to higher-level machining topics, as well as professional engineers and technicians. All chapters are updated, with additional chapters covering new topics of composite machining, vibration assisted machining and mass finishing operations. Features Presents a wide spectrum of metal cutting, abrasive machining, nonconventional and hybrid machining processes Analyzes the chip formation in machining by cutting and abrasion processes as well as the material removal mechanisms in the nonconventional and the hybrid processes Explains the role of each process variables on its behavior and technological characteristics in terms of material removal, product accuracy and surface quality Portrays the theoretical and empirical formula for removal rates and surface finish in different processes as well as very useful technical data that help in solving and analysis of day-to-day shop floor problems that face manufacturing engineers Clarifies the machinability concept and introduces the general guidelines for machining process selection