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Tribology and Fundamentals of Abrasive Machining Processes
- 3rd Edition - November 10, 2021
- Authors: Bahman Azarhoushang, Ioan D. Marinescu, W. Brian Rowe, Boris Dimitrov, Hitoshi Ohmori
- Language: English
- Paperback ISBN:9 7 8 - 0 - 1 2 - 8 2 3 7 7 7 - 9
- eBook ISBN:9 7 8 - 0 - 1 2 - 8 2 3 7 7 8 - 6
This new edition draws upon the fundamentals of abrasive machining processes and the science of tribology to understand, predict, and improve abrasive machining processes. Each of… Read more
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Request a sales quoteThis new edition draws upon the fundamentals of abrasive machining processes and the science of tribology to understand, predict, and improve abrasive machining processes. Each of the main elements of the abrasive machining system is looked at alongside the tribological factors that control the efficiency and quality of the processes described. The new edition has been updated to include a variety of industrial applications. Grinding and conditioning of grinding tools are dealt with in particular detail, and solutions are proposed for many of the most commonly experienced industrial problems, such as poor accuracy, poor surface quality, rapid tool wear, vibrations, workpiece burn, and high process costs. The entire book has been rewritten and restructured, with ten completely new chapters. Other new features include:
- Extensive explanations of the main abrasive machining processes such as grinding (including reciprocating and creep-feed grinding, high-speed high-efficiency deep grinding, external and internal cylindrical grinding, and centerless grinding), honing, superfinishing, lapping, polishing, and finishing
- Discussions of the new classes of abrasives, abrasive tools, and bonding materials
- New case studies and troubleshooting on the most common grinding practices
- New coverage on grinding tool conditioning, mechanical dressing, and nonmechanical dressing processes
- Detailed explanations of the effects of process input parameters (such as cutting parameters, workpiece material and geometry, and abrasive tools) on process characteristics, workpiece quality, tool wear, and process parameters (such as cutting forces and temperature as well as achievable material removal rate)
- Updated topics regarding process fluids for abrasive machining and fluid delivery
Academics and upper level undergrad/grad students in mechanical engineering and machining/manufacturing. Professional mechanical engineers and machinists/manufacturers
- Cover image
- Title page
- Table of Contents
- Copyright
- Dedication
- List of contributors
- About the authors
- Preface to the first edition
- Preface to the second edition
- Preface to the third edition
- Acknowledgments
- Part One. Science of abrasive machining and tribology (introduction)
- 1. Abrasives
- 1.1. Introduction
- 1.2. Corundum
- 1.3. Silicon carbide
- 1.4. Diamond
- 1.5. Cubic boron nitride
- 1.6. Lapping and polishing abrasives
- 1.7. Abrasive sizes and shapes
- 2. Abrasive tools
- 2.1. Introduction
- 2.2. Bonded abrasives
- 2.3. Coated abrasives and abrasive belts
- 2.4. Loose abrasives and abrasive pastes
- 3. Abrasive machining processes
- 3.1. Introduction
- 3.2. Bonded and coated abrasive processes
- 3.3. Loose abrasive processes
- 4. Tribosystems of abrasive machining processes
- 4.1. Introduction
- 4.2. Tribological principles
- 4.3. Structure of tribomechanical processing
- 4.4. Tribosystems in abrasive machining
- 4.5. Modeling tribosystems of abrasive processes
- 4.6. Conclusions
- Part Two. Principles of abrasive machining processes
- 5. Kinematics of bonded abrasive machining processes
- 5.1. Introduction
- 5.2. Chip thickness or grain penetration depth
- 5.3. Equivalent chip thickness
- 5.4. Cutting edge density
- 5.5. Grain spacing
- 5.6. Variability of active cutting edge density
- 5.7. Mean chip volume
- 5.8. Grain shapes
- 5.9. Geometric contact length
- 5.10. Kinematic contact length
- 5.11. Mean uncut chip cross-sectional area
- 5.12. Irregular grain spacing
- 5.13. Irregular grain protrusion
- 5.14. Contact times and tribological implications
- 6. Material removal mechanisms of bonded abrasive machining (forces, friction, and energy)
- 6.1. Introduction
- 6.2. Removal mechanism of ductile materials
- 6.3. Removal mechanism of brittle materials
- 6.4. Forces and power
- 6.5. Force ratio and friction coefficient
- 6.6. Specific energy
- 6.7. Size effect
- 6.8. Chip formation, sliding, and ploughing energies
- 6.9. Specific removal rate
- 6.10. Energy partition
- 7. Contact mechanics
- 7.1. Introduction
- 7.2. Contact area
- 7.3. Contact length
- 7.4. Smooth body analysis
- 7.5. Rough surface analysis
- 7.6. Experimental measurements of the roughness factor
- 7.7. Elastic stresses due to abrasion
- 7.8. Indentation mechanics approach
- 7.9. Summary
- 8. Grinding wheel macrodesign and microtopography
- 8.1. Introduction
- 8.2. Wheel body and shape
- 8.3. The importance of microtopography
- 8.4. Topographical definitions
- 8.5. Measurement techniques for grinding tool microtopography
- 8.6. Topography changes in grinding
- 9. Grinding tool conditioning
- 9.1. Introduction
- 9.2. Dressing, cleaning, and structuring
- 9.3. Dressing methods
- 9.4. Mechanical dressing processes
- 9.5. Tribology of mechanical dressing
- 9.6. Diamond types for dressing tools
- 9.7. Dressing with stationary diamond tools
- 9.8. Rotary dressing tools
- 9.9. Diamond form rollers
- 9.10. Diamond profile rollers
- 9.11. Diamond cup dresser
- 9.12. Continuous dressing
- 9.13. Crushing
- 9.14. Touch dressing
- 9.15. Cross-axis dressing
- 9.16. Wear and tool life of diamond dressing tools
- 9.17. Mechanical dressing of resin-, metal-, and hybrid-bonded grinding wheels
- 9.18. Sharpening
- 9.19. Removal mechanisms in mechanical dressing processes
- 9.20. Nonconventional conditioning processes
- 9.21. Summary
- 10. Principles of grinding processes
- 10.1. Overview of the grinding process
- 10.2. External cylindrical grinding between centers
- 10.3. External cylindrical centerless grinding
- 10.4. Surface grinding
- 10.5. Internal cylindrical grinding
- 11. Cutting temperature and energy partitioning in grinding
- 11.1. Introduction
- 11.2. Heat generation and dissipation
- 11.3. Measuring and estimating temperatures
- 11.4. Heat partitioning
- 11.5. Workpiece temperatures
- 11.6. Case studies
- 12. Kinematics and material removal mechanisms of loose abrasive machining
- 12.1. Introduction
- 12.2. Lapping
- 12.3. Polishing
- 12.4. Mass finishing and tumbling
- 12.5. Chemomechanical polishing
- Part Three. Tool wear, induced surface integrity of workpiece material, and machineability of materials
- 13. Mechanisms of tool wear
- 13.1. Introduction
- 13.2. Wear types and mechanisms
- 13.3. Analysis of adhesive and abrasive wear
- 13.4. Abrasive tool loading or clogging
- 13.5. G-ratio
- 13.6. Tool wear and loading measurement
- 14. Thermal aspects of abrasive machining processes
- 14.1. Introduction
- 14.2. Grinding burn
- 14.3. Surface damage
- 14.4. Thermal softening
- 14.5. Rehardening
- 14.6. Crack formation
- 14.7. Microhardness
- 14.8. Residual stresses
- 14.9. Spheroidal swarf
- 15. Workpiece surface roughness
- 15.1. Introduction
- 15.2. Surface roughness parameters
- 15.3. Factors affecting surface roughness
- 15.4. Measurement of surface roughness
- 15.5. Application of acoustic emission to predict surface roughness behavior
- 16. Machinability of materials
- 16.1. Introduction
- 16.2. Metals
- 16.3. Structural aspects and machinability of nonmetals
- 16.4. Conclusions
- Part Four. Process fluids and tribochemistry of abrasive machining
- 17. Process fluids for abrasive machining
- 17.1. Introduction
- 17.2. Types and classes of process fluids
- 17.3. Physical properties of process fluids
- 17.4. Chemical properties of process fluids
- 17.5. Tribological properties of process fluids
- 17.6. Biological properties of process fluids
- 17.7. Degradation of fluid properties during operation
- 17.8. Analysis of physicochemical and biological properties
- 17.9. Tribological and application characteristics
- 17.10. Selection of process fluids
- 17.11. Adjustment and maintenance of fluid properties in operation
- 17.12. Disposal of process fluids
- 17.13. Conclusions and recommendations
- 18. Fluid delivery
- 18.1. Introduction
- 18.2. The tasks and role of process fluid supply
- 18.3. Cooling and lubrication techniques
- 18.4. Process fluid delivery and supply system
- 18.5. Considerations and challenges of process fluid delivery
- 18.6. Fluid nozzles for high-performance grinding processes
- 19. Tribochemistry of abrasive machining
- 19.1. Introduction
- 19.2. Tribochemical behavior of abrasive tools
- 19.3. Tribochemical aspects of the workpiece material structure
- 19.4. Tribochemical aspects of dry abrasive machining
- 19.5. Tribochemical aspects of wet abrasive machining
- 19.6. Conclusions
- Symbols and abbreviations
- Index
- No. of pages: 770
- Language: English
- Edition: 3
- Published: November 10, 2021
- Imprint: William Andrew
- Paperback ISBN: 9780128237779
- eBook ISBN: 9780128237786
BA
Bahman Azarhoushang
Bahman Azarhoushang has been a Professor of Mechanical and Medical Engineering at Furtwangen University (Germany) since 2013, where he also serves as the Head of the Center for Excellence in Machining. There he has access to various modern CNC machine tools and measuring devices. He has published more than 160 publications in various languages (with more than 60 publications in peer-reviewed journals) and lectured at numerous national and international conferences. He has authored several books and patents in the field of abrasive and precision machining. He is the editor of various international journals and co-authored the 3rd edition of ‘Tribology and Fundamentals of Abrasive Machining Processes’ (Elsevier). He teaches courses in Manufacturing Engineering, Machine Tools, Production Metrology, and Precision Manufacturing. His main research areas are conditioning (mechanical and nonmechanical dressing) and grinding (high-speed, high-efficiency grinding; nonconventional grinding), precision machining, tribology, innovative tools, the creation of extremely fine surfaces and structures, and process optimization.
Affiliations and expertise
Professor of Mechanical and Medical Engineering, Furtwangen University, Furtwangen im Schwarzwald, GermanyIM
Ioan D. Marinescu
Ioan D. Marinescu is Professor and Director of the Precision Micromachining Center at The University of Toledo, Ohio, USA, and CEO of Advanced Manufacturing Solutions, LLC. His research interests include manufacturing processes, grinding, tribology, advanced materials, and machining of brittle materials.
Affiliations and expertise
Professor and Director, Precision Micromachining Center, The University of Toledo, Toledo, OH, USAWR
W. Brian Rowe
W. Brian Rowe is Consulting Director and Emeritus Professor of Mechanical Engineering at Liverpool John Moores University, Liverpool, UK. He is also former Director of the Advanced Manufacturing Technology and Tribology Research Laboratory. Professor Rowe is a widely respected researcher in the fields of tribology and grinding. He has authored many books on grinding and grinding machine technology, also on bearing analysis and design.
Affiliations and expertise
Consulting Director and Emeritus Professor of Mechanical Engineering at Liverpool John Moores University, Liverpool, UKBD
Boris Dimitrov
Boris Dimitrov is a Consulting Engineer in mechanics and chemistry, former Chief Scientist of the Romanian Research Institute of Applied Mechanics, and a former member of the Romanian Institute for Precision Mechanics in Bucharest.
Affiliations and expertise
Romanian Research Institute for Applied Mechanics and Institute for Precision Mechanics, Bucharest, RomaniaHO
Hitoshi Ohmori
Hitoshi Ohmori is Chief Scientist at the Materials Fabrication Laboratory, RIKEN, Wakō, Saitama, Japan.
Affiliations and expertise
Chief Scientist, Materials Fabrication Laboratory, RIKEN, Wakō, Saitama, Japan