Modern Manufacturing Processes

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.

• Foreword xviiList of Contributors xixPart I Advanced Forming Processes 11 Advances in Stamping 3Ilyas Kacar and Fahrettin Ozturk1.1 Introduction 3References 132 Hydroforming 15C Hartl2.1 Introduction 152.2 Fundamentals 162.3 Process Development and Design 332.4 Hydroforming Systems 372.5 Concluding Remarks 39References 403 Incremental Sheet Forming 47Rogelio Perez‐Santiago, Isabel Bagudanch, and Maria Luisa Garcia‐Romeu3.1 Incremental Sheet Forming: General Overview 473.2 ISF Variants 493.3 Process Cycle 513.4 Materials 523.5 Formability in ISF 523.6 ISF Process Parameters 553.7 Accuracy 553.8 Simulation 573.9 Future Trends in ISF 583.10 Case Study 593.11 Concluding Remarks 59References 604 Powder Forming 65Rahmi Unal4.1 Introduction 654.2 Reasons for Using PM Route 674.3 Powder Production 694.4 Consolidation Techniques 734.5 Sintering 794.6 Powder Injection Molding (PIM) 824.7 Summary and Future Work 84References 855 Injection Molding at Multiscales 89Danyang Zhao, Minjie Wang, and Donggang Yao5.1 Introduction 895.2 Overview of Injection Molding 915.3 Injection Molding of Precision Parts 1055.4 Injection Molding of Thin Wall Parts 1095.5 Injection Molding of Microstructured Parts 1165.6 Injection Molding of Microparts 1245.7 Simulation of Injection Molding 1275.8 Summary and Outlook 131References 1326 Manufacturing Techniques of Bulk Metallic Glasses 137Mustafa Bakkal, Umut Karaguzel, and Ali T. Kuzu6.1 Introduction 1376.2 Mechanical Properties and Usage of Bulk Metallic Glasses 1396.3 Rapid Quenching Methods 1406.4 Water‐Quenching Method 1416.5 Arc Melting Drop/Suction Casting Method 1426.6 High‐Pressure Die Casting Method 1436.7 Copper Mold Casting Method 1446.8 Cap Casting Method 1446.9 Centrifugal Casting Method 1456.10 Metal Foaming Method 1466.11 Concluding Remarks 147References 1477 Micromanufacturing 149Omer N. Cora and Muammer Koc7.1 Introduction 1497.2 Classification of Micromanufacturing Processes 1507.3 Micromanufacturing Processes 154References 179Part II Thermal and Energy‐assisted Manufacturing Processes 1858 Warm Stamping 187Fahrettin Ozturk , Serkan Toros, and Ilyas Kacar8.1 What is Stamping? 1878.2 Benefits and Usage Areas of Warm Stamping 1878.3 Warm Stamping and Recent Developments 1888.4 Effects of Temperature on Strain Hardening for Warm Stamping 1948.5 Interrelation of Temperature and Strain Rate 1968.6 Effect of Temperature and Deformation on Elasticity Modulus 1988.7 Effect of Temperature on Springback 2018.8 Effect of Temperature on Forming Limit Diagrams (FLD) 2048.9 Analyze Techniques on Formability at Warm Stamping 2058.10 The Effects of Lubrication 2158.11 Future Directions 215References 2169 Warm Hydroforming 219Muammer Koc, Omer N. Cora, Huseyin S. Halkacı, and Mevlut Turkoz9.1 Introduction 2199.2 Warm Sheet Hydroforming 2209.3 Warm Hydromechanical Deep Drawing 2309.4 Warm Tube Hydroforming 231References 23710 Hot Stamping 239Fahrettin Ozturk , Ilyas Kacar, and Muammer Koc10.1 Introduction 23910.2 Process Description and Motivation 24010.3 Why Hot Stamping? 24110.4 Automotive Parts by Hot Stamping and Potentials 24110.5 Advantages and Disadvantages 24310.6 Process Description and Methods 24510.7 Cooling for Hot Stamping 25410.8 Process Control 25510.9 Modeling and Analysis 25510.10 Design and Optimization in Hot Stamping 25610.11 FEA in Hot Stamping 25710.12 Research and Development Trends and Needs 258References 26211 High‐Speed Forming (Electromagnetic, Electrohydraulic, and Explosive Forming) 265Brad Kinsey and Yannis Korkolis11.1 Introduction 26511.2 Electromagnetic Forming and Magnetic Pulsed Welding 26711.3 Electrohydraulic Forming 27411.4 Explosive Forming 27911.5 Emerging Technologies 28211.6 Metrology and Measurements 28411.7 Material Characterization 28611.8 Modeling of High‐Speed Forming Processes 28811.9 Summary and Future Work 291References 292Part III Advanced Material Removal Processes 29512 High‐Speed Machining 297Elisa Vazquez and Guillem Quintana12.1 High‐Speed Machining Overview 29712.2 High‐Speed Machining Processes and Capabilities 29812.3 Machine Tools for High‐Speed Machining 29812.4 Tools for High‐Speed Machining 30012.5 High‐Speed Machining Applications and Future Trends 305References 30613 Hard Machining 309Durul Ulutan and Tuğrul Ozel13.1 Introduction 30913.2 Mechanics of Hard Machining 31213.3 Cutting Tools 31313.4 Surface Quality and Integrity 31613.5 Summary and Conclusions 320References 32014 Advances in Material Modeling for Manufacturing Analysis and Simulation (Deformation and Cutting Processes) 323Elisabetta Ceretti, Claudio Giardini, and Antonio Fiorentino14.1 Introduction on Material Characterization and Modeling 32314.2 Material Models and Applications 32414.3 Failure Models 32714.4 Modeling of Contact, Friction, and Wear 331References 34715 Advanced Grinding 351Taghi Tawakoli and Amir Daneshi15.1 Introduction 35115.2 Grinding Wheels 35115.3 Bond Materials 35315.4 Grinding Wheel Conditioning 35415.5 Grinding Force and Energy 36315.6 Thermal Damages in Grinding 36315.7 Environmentally Friendly Grinding 36415.8 High‐efficiency Deep Grinding (HEDG) 36715.9 Ultrasonic‐Assisted Grinding (UAG) 36715.10 Ultrasonic‐Assisted Dressing 371References 37316 Electro‐Discharge Machining (EDM) 377Muhammad P. Jahan16.1 Introduction 37716.2 Principle of the EDM Process 37816.3 EDM System Components 37916.4 Analysis of the Pulses Used in the EDM Process 38316.5 Brief Overview of the EDM Parameters 38416.6 EDM Variants: Working Principles and Application Examples 38516.7 Examples of Research Advances in EDM and Micro‐EDM 39316.8 Research Focus Toward Micro‐ and Nano‐EDM 40216.9 Summary 403References 40417 MicroMilling Operations 411Simon S. Park, Martin B.G. Jun, and Gerardo Garcia17.1 Introduction 41117.2 Machine Tools for Micromilling 41317.3 Micromilling Forces 42017.4 Tool Tip Dynamics 42717.5 Summary 430References 43118 Laser Machining 427Dani Teixidor, Ines Ferrer, Luis Criales, and Tuğrul Ozel18.1 Introduction 43518.2 Laser–Material Interaction 43718.3 Laser Processing of Materials 43818.4 Laser‐Processing Parameters 44218.5 Laser Drilling 44518.6 Laser Cutting 44818.7 Laser Milling 45018.8 Concluding Remarks 452References 45319 Laser‐assisted Machining Operations 459Eneko Ukar, Ivan Tabernero, Silvia Martinez, Aitzol Lamikiz, and Asier Fernandez19.1 Introduction 45919.2 Heat‐assisted Processes 46019.3 Analysis of LAM Processes 47019.4 Laser‐assisted Applications 47419.5 Conclusions 477References 47820 Selective Laser Sintering 481Jordi Delgado, Lidia Sereno, Karla Monroy, and Joaquim Ciurana20.1 General Overview 48120.2 Mechanisms 48320.3 Process Parameters 48620.4 Materials 49020.5 Capabilities and Limitations 494References 496Index 501

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