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2021 | Book

General Characteristics of Material Shaping Processes Read chapter Read first chapter

Hybrid Manufacturing Processes

Physical Fundamentals, Modelling and Rational Applications

Authors: Prof. Dr. Wit Grzesik, Prof. Adam Ruszaj

Publisher: Springer International Publishing

Book Series : Springer Series in Advanced Manufacturing

Part of: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik" , Springer Professional "Wirtschaft"

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About this book

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.

Table of Contents

Frontmatter
Chapter 1. General Characteristics of Material Shaping Processes
Abstract
Material removal process (machining) is one of the five basic groups of all manufacturing technologies presented.
Wit Grzesik, Adam Ruszaj
Chapter 2. Classification of Hybrid Machining Processes Generating by Different Rules
Abstract
The evolution of conventional and unconventional machining processes in the period after the Second World War is inextricably linked to the combination of individual processes and the use of different active energy sources or the implementation of several machining methods or even several subsequent stages of the technological process, in a single production unit in order to achieve the synergy effect.
Wit Grzesik, Adam Ruszaj
Chapter 3. Application of Hybrid Machining Processes in Industry
Abstract
From the previous considerations it follows that hybrid processes are an important element in modern manufacturing systems. By using a hybrid process, it is possible to significantly increase the capacity and efficiency of manufacturing processes in relation to the capacity of the componential processes.
Wit Grzesik, Adam Ruszaj
Chapter 4. Physical Fundamentals of Conventional and Unconventional Machining Processes
Abstract
In conventional subtractive machining—cutting and abrasive machining processes, the material removal is performed by overcoming the cohesion forces of the material due to various decohesion (material separation) mechanisms, particularly ductile (plastic)fracture, partially ductile fracture and brittle fracture.
Wit Grzesik, Adam Ruszaj
Chapter 5. Modelling of Hybrid Machining Processes
Abstract
Material removal in cutting and abrasive processes takes place under complex thermo-mechanical, and often thermo-mechanical-chemical conditions.
Wit Grzesik, Adam Ruszaj
Chapter 6. Vibration-Assisted Machining Processes
Abstract
Vibration assisted machining (VAM) is the kind of assisted machining process which utilizes additional external mechanical energy source of vibrations with a small amplitude of 1–200 µm and frequencies of 0.1–80 kHz (typically about 10 µm and ultrasonic (US) frequency, i.e. within the frequency range of 18 kHz to 25 kHz).
Wit Grzesik, Adam Ruszaj
Chapter 7. Media-Assisted Machining Processes
Abstract
It should be reminded that in the general classification of hybrid shaping processes.
Wit Grzesik, Adam Ruszaj
Chapter 8. Magnetic and Electric Field-Assisted Machining Processes
Abstract
During a long time the development of unconventional material removal processes in relation to traditionally used metallic and no-metallic materials substantially progressed but recently a variety of new advanced materials, which allow to improve part functionality, and corresponding manufacturing methods have been dynamically investigated and utilized in many industry branches.
Wit Grzesik, Adam Ruszaj
Chapter 9. Thermally-Assisted Machining Processes
Abstract
Thermally assisted machining (TAM) is an effective method of cost-effective production of high quality parts by increasing process efficiency, improving dimensional control, reducing componential cutting forces, increasing tool life and reducing surface defects when machining materials such as superalloys and ceramics and when using micro tools with limited strength.
Wit Grzesik, Adam Ruszaj
Chapter 10. Mixed Hybrid Processes
Abstract
Mixed or combined hybrid machining processes are basically classified within group (I) of the CIRP classification system of manufacturing processes.
Wit Grzesik, Adam Ruszaj
Chapter 11. Hybrid Processes with Controlled Mechanisms
Abstract
In the second CIRP group (II) some hybrid processes with controlled application of their individual mechanisms are selected (Sect. 1.3). They cover two subtractive and transformative processes (as for instance grind-hardening or sequential cutting and sliding/roller burnishing) or two transformative processes (as for instance cryogenic deep rolling when the machining zone is cryogenically cooled by CO2 snow).
Wit Grzesik, Adam Ruszaj
Chapter 12. Hybrid Additive and Subtractive Processes
Abstract
The realisation of the Manufacturing 4.0 strategy is closely linked to the hybridisation of manufacturing processes, as signalled in Sect. 1.4. The scope now also includes hybrid processes and equipment that combine Layered/Additive Machining (LM/AM) and Subtractive Machining (SM) CNC (LM/SM CNC) which are not included in the basic classification of hybrid machining processes.
Wit Grzesik, Adam Ruszaj
Chapter 13. Economics and Optimization Strategies of Hybrid Processes
Abstract
Economic aspects are obviously important in the design of technological chain and planning a machining process taking into account costs involved. Among the total costs such components as the machining cost, tool cost, tool change and its setup costs, and handling costs are considered in the cost analysis.
Wit Grzesik, Adam Ruszaj
Chapter 14. Influence of Process Hybridization on Surface Integrity
Abstract
In material removal processes the material layer localized beneath the real surface, which is affected by different process alterations including physical (heat, forces, diffusion or foreign atoms), chemical (i.e. oxidation) and structural (metallurgical changes, phase transformations) influences is termed subsurface layer or superficial layer.
Wit Grzesik, Adam Ruszaj
Metadata
Title
Hybrid Manufacturing Processes
Authors
Prof. Dr. Wit Grzesik
Prof. Adam Ruszaj
Copyright Year
2021
Electronic ISBN
978-3-030-77107-2
Print ISBN
978-3-030-77106-5
DOI
https://doi.org/10.1007/978-3-030-77107-2

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