Cover
Foreword
List of Contributors
Part I: Advanced Forming Processes
1. 1 Advances in Stamping
  1. 1.1 Introduction
  2. References
2. 2 Hydroforming
  1. 2.1 Introduction
  2. 2.2 Fundamentals
  3. 2.3 Process Development and Design
  4. 2.4 Hydroforming Systems
  5. 2.5 Concluding Remarks
  6. References
3. 3 Incremental Sheet Forming
  1. 3.1 Incremental Sheet Forming: General Overview
  2. 3.2 ISF Variants
  3. 3.3 Process Cycle
  4. 3.4 Materials
  5. 3.5 Formability in ISF
  6. 3.6 ISF Process Parameters
  7. 3.7 Accuracy
  8. 3.8 Simulation
  9. 3.9 Future Trends in ISF
  10. 3.10 Case Study
  11. 3.11 Concluding Remarks
  12. References
4. 4 Powder Forming
  1. 4.1 Introduction
  2. 4.2 Reasons for Using PM Route
  3. 4.3 Powder Production
  4. 4.4 Consolidation Techniques
  5. 4.5 Sintering
  6. 4.6 Powder Injection Molding (PIM)
  7. 4.7 Summary and Future Work
  8. References
5. 5 Injection Molding at Multiscales
  1. 5.1 Introduction
  2. 5.2 Overview of Injection Molding
  3. 5.3 Injection Molding of Precision Parts
  4. 5.4 Injection Molding of Thin Wall Parts
  5. 5.5 Injection Molding of Microstructured Parts
  6. 5.6 Injection Molding of Microparts
  7. 5.7 Simulation of Injection Molding
  8. 5.8 Summary and Outlook
  9. References
6. 6 Manufacturing Techniques of Bulk Metallic Glasses
  1. 6.1 Introduction
  2. 6.2 Mechanical Properties and Usage of Bulk Metallic Glasses
  3. 6.3 Rapid Quenching Methods
  4. 6.4 Water‐Quenching Method
  5. 6.5 Arc Melting Drop/Suction Casting Method
  6. 6.6 High‐Pressure Die Casting Method
  7. 6.7 Copper Mold Casting Method
  8. 6.8 Cap Casting Method
  9. 6.9 Centrifugal Casting Method
  10. 6.10 Metal Foaming Method
  11. 6.11 Concluding Remarks
  12. References
7. 7 Micromanufacturing
  1. 7.1 Introduction
  2. 7.2 Classification of Micromanufacturing Processes
  3. 7.3 Micromanufacturing Processes
  4. References
Part II: Thermal and Energy-assisted Manufacturing Processes
1. 8 Warm Stamping
  1. 8.1 What Is Stamping?
  2. 8.2 Benefits and Usage Areas of Warm Stamping
  3. 8.3 Warm Stamping and Recent Developments
  4. 8.4 Effects of Temperature on Strain Hardening for Warm Stamping
  5. 8.5 Interrelation of Temperature and Strain Rate
  6. 8.6 Effect of Temperature and Deformation on Elasticity Modulus
  7. 8.7 Effect of Temperature on Springback
  8. 8.8 Effect of Temperature on Forming Limit Diagrams (FLD)
  9. 8.9 Analyze Techniques on Formability at Warm Stamping
  10. 8.10 The Effects of Lubrication
  11. 8.11 Future Directions
  12. References
2. 9 Warm Hydroforming
  1. 9.1 Introduction
  2. 9.2 Warm Sheet Hydroforming
  3. 9.3 Warm Hydromechanical Deep Drawing
  4. 9.4 Warm Tube Hydroforming
  5. References
3. 10 Hot Stamping
  1. 10.1 Introduction
  2. 10.2 Process Description and Motivation
  3. 10.3 Why Hot Stamping?
  4. 10.4 Automotive Parts by Hot Stamping and Potentials
  5. 10.5 Advantages and Disadvantages
  6. 10.6 Process Description and Methods
  7. 10.7 Cooling for Hot Stamping
  8. 10.8 Process Control
  9. 10.9 Modeling and Analysis
  10. 10.10 Design and Optimization in Hot Stamping
  11. 10.11 FEA in Hot Stamping
  12. 10.12 Research and Development Trends and Needs
  13. References
4. 11 High‐Speed Forming (Electromagnetic, Electrohydraulic, and Explosive Forming)
  1. 11.1 Introduction
  2. 11.2 Electromagnetic Forming and Magnetic Pulsed Welding
  3. 11.3 Electrohydraulic Forming
  4. 11.4 Explosive Forming
  5. 11.5 Emerging Technologies
  6. 11.6 Metrology and Measurements
  7. 11.7 Material Characterization
  8. 11.8 Modeling of High‐Speed Forming Processes
  9. 11.9 Summary and Future Work
  10. References
Part III: Advanced Material Removal Processes
1. 12 High‐Speed Machining
  1. 12.1 High‐Speed Machining Overview
  2. 12.2 High‐Speed Machining Processes and Capabilities
  3. 12.3 Machine Tools for High‐Speed Machining
  4. 12.4 Tools for High‐Speed Machining
  5. 12.5 High‐Speed Machining Applications and Future Trends
  6. References
2. 13 Hard Machining
  1. 13.1 Introduction
  2. 13.2 Mechanics of Hard Machining
  3. 13.3 Cutting Tools
  4. 13.4 Surface Quality and Integrity
  5. 13.5 Summary and Conclusions
  6. References
3. 14 Advances in Material Modeling for Manufacturing Analysis and Simulation (Deformation and Cutting Processes)
  1. 14.1 Introduction on Material Characterization and Modeling
  2. 14.2 Material Models and Applications
  3. 14.3 Failure Models
  4. 14.4 Modeling of Contact, Friction, and Wear
  5. References
4. 15 Advanced Grinding
  1. 15.1 Introduction
  2. 15.2 Grinding Wheels
  3. 15.3 Bond Materials
  4. 15.4 Grinding Wheel Conditioning
  5. 15.5 Grinding Force and Energy
  6. 15.6 Thermal Damages in Grinding
  7. 15.7 Environmentally Friendly Grinding
  8. 15.8 High‐efficiency Deep Grinding (HEDG)
  9. 15.9 Ultrasonic‐Assisted Grinding (UAG)
  10. 15.10 Ultrasonic‐Assisted Dressing
  11. References
5. 16 Electro‐Discharge Machining (EDM)
  1. 16.1 Introduction
  2. 16.2 Principle of the EDM Process
  3. 16.3 EDM System Components
  4. 16.4 Analysis of the Pulses Used in the EDM Process
  5. 16.5 Brief Overview of the EDM Parameters
  6. 16.6 EDM Variants: Working Principles and Application Examples
  7. 16.7 Examples of Research Advances in EDM and Micro‐EDM
  8. 16.8 Research Focus Toward Micro‐ and Nano‐EDM
  9. 16.9 Summary
  10. References
6. 17 MicroMilling Operations
  1. 17.1 Introduction
  2. 17.2 Machine Tools for Micromilling
  3. 17.3 Micromilling Forces
  4. 17.4 Tool Tip Dynamics
  5. 17.5 Summary
  6. References
7. 18 Laser Machining
  1. 18.1 Introduction
  2. 18.2 Laser–Material Interaction
  3. 18.3 Laser Processing of Materials
  4. 18.4 Laser‐Processing Parameters
  5. 18.5 Laser Drilling
  6. 18.6 Laser Cutting
  7. 18.7 Laser Milling
  8. 18.8 Concluding Remarks
  9. References
8. 19 Laser‐assisted Machining Operations
  1. 19.1 Introduction
  2. 19.2 Heat‐assisted Processes
  3. 19.3 Analysis of LAM Processes
  4. 19.4 Laser‐assisted Applications
  5. 19.5 Conclusions
  6. References
9. 20 Selective Laser Sintering
  1. 20.1 General Overview
  2. 20.2 Mechanisms
  3. 20.3 Process Parameters
  4. 20.4 Materials
  5. 20.5 Capabilities and Limitations
  6. References
Index
End User License Agreement

List of Tables

Chapter 3
1. Table 3.1 Summary of the main process parameters in ISF.
Chapter 4
1. Table 4.1 Key structure property relationships in RSP materials.
2. Table 4.2 Typical compacting pressures for various applications.
3. Table 4.3 Sintering temperatures for powder metal alloys and special ce...
Chapter 5
1. Table 5.1 Polymer materials often used in injection molding at multisca...
2. Table 5.2 Parameters of different precision injection molding machines.
3. Table 5.3 Constituent elements and building blocks for mold rapid therm...
4. Table 5.4 The levels of factors.
5. Table 5.5 Experimental design and results.
6. Table 5.6 Polymers for injection molding of microstructured parts.
7. Table 5.7 A summary of different DOE studies on microinjection molding.
8. Table 5.8 Comparison of the simulation studies for miniature injection ...
Chapter 6
1. Table 6.1 Critical cooling rates and section thicknesses for glass form...
2. Table 6.2 Comparison of properties of Zr‐based bulk metallic glass (BMG...
3. Table 6.3 Already commercialized and possible applications of BMG.
Chapter 7
1. Table 7.1 Micromachining categorization based on the effect of process.
2. Table 7.2 Micromanufacturing process categorization.
3. Table 7.3 Micromacturing classification.
4. Table 7.4 Micro molding applications in different industries [60–64].
5. Table 7.5 Common laser micromachining application in various sectors, a...
Chapter 9
1. Table 9.1 Increasing of the limiting drawing ratio.
Chapter 10
1. Table 10.1 Optimal hot stamping temperature values of various materials...
2. Table 10.2 The mechanical characteristics of some AHSS materials.
3. Table 10.3 Typical values of temperature, strain‐rate sensitivity, and ...
Chapter 13
1. Table 13.1 Comparison of cutting tool materials and key properties.
Chapter 14
1. Table 14.1 Comparison of the accuracy of different material models.
2. Table 14.2 Preferred material models for different processes.
3. Table 14.3 Die geometry for each extrusion pass.
Chapter 17
1. Table 17.1 Comparison and challenges associated with macromachining vs....
2. Table 17.2 Cutting constants for Al 7075 at 60 000 rev/min, 50 μm depth...
Chapter 18
1. Table 18.1 Commonly used lasers in industry.
Chapter 19
1. Table 19.1 Shapes and equations of energy sources for different types o...
Chapter 20
1. Table 20.1 Material properties and effect on the laser sintering proces...

List of Illustrations

Chapter 1
1. Figure 1.1 Schematic of a stamping process.
2. Figure 1.2 Deformation sequences for three drawbead geometries (a) dome (R
3. Figure 1.3 Some defects on stamping deformed without drawbead.
4. Figure 1.4 Drawbead types.
5. Figure 1.5 Sidewall curl occurrences.
6. Figure 1.6 Active drawbead penetration control of sheet metal forming.
7. Figure 1.7 An example path for an active drawbead.
8. Figure 1.8 Variable force binder: actuator segments and their hexagonal ar...
9. Figure 1.9 Variable binder force control using height‐adjustable die cushi...
10. Figure 1.10 (a) Restraining force comparison. (b) EMBR assembly in the die...
11. Figure 1.11 Schematic representation of segmented die with local adaptive ...
12. Figure 1.12 Schematic illustration of multi point forming process of sheet...
Chapter 2
1. Figure 2.1 Principle of tube hydroforming. (a) Start of process and (b) ex...
2. Figure 2.2 Classification of hydroforming processes. (a) Hydroforming proc...
3. Figure 2.3 Principles of tube hydroforming processes with internal pressur...
4. Figure 2.4 Examples of components manufactured by tube hydroforming. (a) E...
5. Figure 2.5 Principle of tube hydroforming with external pressurization. 1,...
6. Figure 2.6 Principles of high‐pressure sheet forming processes. (a) Single...
7. Figure 2.7 Example of a high‐pressure sheet formed body component.
8. Figure 2.8 Principle of hydromechanical deep drawing. 1, Initial blank; 2,...
9. Figure 2.9 Combination of deep drawing and subsequent hydroforming accordi...
10. Figure 2.10 Process sequence of tube processes with mechanical deep drawin...
11. Figure 2.11 Integrated processes with modification of workpiece longitudin...
12. Figure 2.12 Hydroformed aluminum prototype part with displaced axis.
13. Figure 2.13 Flattening of tubular blanks in hydroforming. 1, Cross section...
14. Figure 2.14 Examples of integrated mechanical forming in sheet hydroformin...
15. Figure 2.15 Integrated collar forming in hydroforming processes. (a) Princ...
16. Figure 2.16 Joining of components by hydroforming for the example of camsh...
17. Figure 2.17 Different joining techniques in hydroforming processes. Source
18. Figure 2.18 Piercing and cutting in hydroforming processes. (a) Outward pi...
19. Figure 2.19 Loads in tube hydroforming.
20. Figure 2.20 Range of process controls for tube hydroforming.
21. Figure 2.21 Process control for hydroforming of a tubular component.
22. Figure 2.22 Loads in high‐pressure sheet forming.
23. Figure 2.23 Range of process controls for high‐pressure sheet forming.
24. Figure 2.24 Schematic representation of process control for high‐pressure ...
25. Figure 2.25 Loads in hydromechanical deep drawing.
26. Figure 2.26 Possible failure modes in hydroforming, schematically. (a) Tub...
27. Figure 2.27 Friction zones in tube hydroforming, according to [71, 72]. 1,...
28. Figure 2.28 Friction zones in high‐pressure sheet hydroforming.
29. Figure 2.29 Effect of different lubricants on wall thickness distribution....
30. Figure 2.30 Classification of hydroformed components.
31. Figure 2.31 Design of tool parting line. (a) Symmetrical die halves with f...
32. Figure 2.32 Examples of tailored blanks. (a) One‐piece cylindrical tube, (...
33. Figure 2.33 Customized blank and tubular product with varying cross sectio...
34. Figure 2.34 Hydroforming tools. (a) Schematic drawing of the cross section...
35. Figure 2.35 Typical principles of hydroforming presses, schematically. (a)...
36. Figure 2.36 Hydroforming production press (50 MN).
Chapter 3
1. Figure 3.1 Graphical representation of the unitary cost as a function of t...
2. Figure 3.2 Evolution of the number of papers published in indexed journals...
3. Figure 3.3 SPIF variant.
4. Figure 3.4 TPIF process variant (a) positive die and (b) negative die.
5. Figure 3.5 Operation principle of the hybrid process (a) experimental setu...
6. Figure 3.6 Experimental set‐up of roboforming.
7. Figure 3.7 (a) FLD regions. (b) FLD in traditional sheet metal forming pro...
8. Figure 3.8 Sine law.
9. Figure 3.9 Geometrical error topologies observed during the SPIF of UWA pa...
10. Figure 3.10 TPIF optimized process map.
11. Figure 3.11 Historical timeline for ISF simulation.
12. Figure 3.12 BMF jaws using the (a and d) SPIF, (b and e) TPIF (single tool...
Chapter 4
1. Figure 4.1 Basic PM process part manufacturing route.
2. Figure 4.2 Reasons for using PM technology.
3. Figure 4.3 A view of the action in a jar mill and brittle (a)/ductile (b) ...
4. Figure 4.4 Density dependence of mechanical properties schematically.
5. Figure 4.5 Powder forming technologies.
6. Figure 4.6 Cold die compaction of powder steps. (a) Die filling, (b) posit...
7. Figure 4.7 Density dependence of properties schematically.
8. Figure 4.8 PM part compaction press types: (a) Single action, (b) double a...
9. Figure 4.9 Constant density lines in cylinders of compacted copper powder....
10. Figure 4.10 Compaction behavior of several metals, shoving how density inc...
11. Figure 4.11 Density effect on the strength and ductility of a forged preal...
12. Figure 4.12 Property dependence on porosity.
13. Figure 4.13 The sequence of steps involved in PIM, where a binder and powd...
Chapter 5
1. Figure 5.1 Injection molded parts: (a) plastic optical lenses, (b) mobile‐...
2. Figure 5.2 Schematic of an injection molding machine.
3. Figure 5.3 Schematic of an injection molding cycle: (a) plasticizing, (b) ...
4. Figure 5.4 Basic structure of an injection mold. 1, Clamping plate of fixe...
5. Figure 5.5 Cross‐section showing hot runner system of plastic injection mo...
6. Figure 5.6 Cell container.
7. Figure 5.7 Venting slots on mold insert.
8. Figure 5.8 Photo of vacuum venting system.
9. Figure 5.9 Cell container pictures: (a) molded without vacuum venting and ...
10. Figure 5.10 Basic structure of in‐mold assembly.
11. Figure 5.11 Picture of micro hinges assembly.
12. Figure 5.12 Two different types of visualization molds: (a) Reflective typ...
13. Figure 5.13 Experimental setup for visualization of melt flow in microflui...
14. Figure 5.14 Melt flow fronts at the different time by visualization.
15. Figure 5.15 Cycle of injection compression molding.
16. Figure 5.16 Cross‐section of mold base for injection compression molding....
17. Figure 5.17 The schematic setup for the RTR molding process.
18. Figure 5.18 RTR mold containing side insulation elements.
19. Figure 5.19 Experimental mold surface temperature of the RTR mold.
20. Figure 5.20 Experimental flow patterns with flow thickness of 0.5 mm at 30...
21. Figure 5.21 Experimental flow patterns with flow thickness of 0.5 mm at 10...
22. Figure 5.22 Experimental flow lengths with flow thickness of 0.5 mm at 30%...
23. Figure 5.23 Experimental flow lengths with flow thickness of 0.5 mm at 100...
24. Figure 5.24 Cavities and runners of a thin wall mold..
25. Figure 5.25 Schematic of electroforming process.
26. Figure 5.26 SEM image of nanogratings on the nickel stamp.
27. Figure 5.27 Schematic of the fabrication steps employed to produce the nan...
28. Figure 5.28 Schematic of the combinatorial technology: (a) micromilling, (...
29. Figure 5.29 SEM images of cell container mold inserts.
30. Figure 5.30 Experimental setup for micro injection molding using AMOTEC wi...
31. Figure 5.31 Stages involved in expansion injection molding: (a) dosing, (b...
Chapter 6
1. Figure 6.1 Zr‐based BMG button and ingot prepared by arc melting and drop ...
2. Figure 6.2 Some common rapid quenching methods. (a) Piston and anvil techn...
3. Figure 6.3 This Pd‐based (Pd₄₀Cu₃₀Ni₁₀P₂₀) sample one of the largest BMG s...
4. Figure 6.4 Schematic picture of the arc melting drop/suction casting syste...
5. Figure 6.5 A set of whole arc melting and suction casting process tooling ...
6. Figure 6.6 Some die‐casting product of the Mg₆₅Cu₂₅Y₁₀ parts.
7. Figure 6.7 Schematic illustration of a copper mold casting equipment.
8. Figure 6.8 A schematic diagram of cap casting method.
9. Figure 6.9 Schematic diagram of the centrifugal casting setup with injecti...
10. Figure 6.10 Ring shape BMG samples, Zr₅₅Al₁₀Ni₅Cu₃₀ alloy produced by cent...
11. Figure 6.11 The cellular structure of the BMG foam.
Chapter 7
1. Figure 7.1 Number of journal papers published per year during 1990–2017 pe...
2. Figure 7.2 Top‐down and bottom‐up manufacturing trends in nanotechnology....
3. Figure 7.3 Process categorization for microsystem and micro‐engineering te...
4. Figure 7.4 (a) A 10 μm diameter end mill shown next to the eye of a ladybu...
5. Figure 7.5 (a) Drill with 50 μm diameter shown next to a ant leg and (b) c...
6. Figure 7.6 (a) A grooving and microturning tool with insert width of 50 μm...
7. Figure 7.7 (a) Scanning electron microscope (SEM) image of a grinding tool...
8. Figure 7.8 Abrasive polishing of V‐grooved surfaces made of optical mold s...
9. Figure 7.9 (a) Ultrasonic vibration‐assisted polishing method and (b) poly...
10. Figure 7.10 Schematic of water jet system.
11. Figure 7.11 Examples of micro abrasive water jet machined parts: (a) Titan...
12. Figure 7.12 Microheaded parts in different scales.
13. Figure 7.13 (a) Cooling fins with high aspect ratio for heat sinks by Micr...
14. Figure 7.14 (a) SEM picture if extruded gear shaft and (b) copper pin with...
15. Figure 7.15 Surface detail of extruded polymer jacket for wire.
16. Figure 7.16 Examples of progressive microforming. (a) Various parts made f...
17. Figure 7.17 (a) Micro deep drawn cup with a initial blank of 20 μm in thic...
18. Figure 7.18 Schematic description of micro stamping process, die dimension...
19. Figure 7.19 Schematics of (a) sheet hydroforming. (b) Tube hydroforming....
20. Figure 7.20 Examples of tube microhydroforming [58, 59].
21. Figure 7.21 (a) Schematic of μ‐MIM process. (b, c) Replica of smallest bon...
22. Figure 7.22 Micro plastic injection molding applications: (a) medical stap...
23. Figure 7.23 Examples to microceramic injection molded parts: (a) pharmaceu...
24. Figure 7.24 The 2D and 3D functional surfaces through powder compaction + ...
25. Figure 7.25 Microfluidic channel on stainless steel by means of electroche...
26. Figure 7.26 Titanium dental implant microstructured with 27 000 hemispheri...
27. Figure 7.27 Schematic of electron beam drilling process.
28. Figure 7.28 Micro holes on a spinning head for glass fiber production.
29. Figure 7.29 Process sequence in deep welding through electron beam (a) Hig...
30. Figure 7.30 Schematic of laser ablation process.
31. Figure 7.31 Laser cut stents (a) Stainless steel stent cut with single mod...
32. Figure 7.32 (a) Hard disk drive and (b) flexure arm schematic showing lase...
33. Figure 7.33 Schematic representation of polymer welding process with laser...
34. Figure 7.34 (a) Hole drilling on Kapton tube with a wall thickness of 140 ...
Chapter 8
1. Figure 8.1 A typical nonisothermal warm forming setup.
2. Figure 8.2 Formability at room and warm temperatures. (a) Aluminum – forme...
3. Figure 8.3 A schema of typical warm stamping process.
4. Figure 8.4 The effect of warm temperatures on FLDs.
5. Figure 8.5 Variation of some mechanical properties with applied temperatur...
6. Figure 8.6 Stretching strain marks (Lüder's band).
7. Figure 8.7 Discontinuous yielding and Lüder's band.
8. Figure 8.8 Effects of temperature and strain rate on flow curves of AZ31 m...
9. Figure 8.9 The variation of elasticity modulus of several materials with t...
10. Figure 8.10 The variation of elasticity modulus with plastic deformation....
11. Figure 8.11 Obtained geometries have some differences from desired geometr...
12. Figure 8.12 Variation of the elastic absorbed energy with temperature.
13. Figure 8.13 Variation of the springback angle with temperature.
14. Figure 8.14 Comparison of springback behaviors of CP2‐Ti alloy sheets at R...
15. Figure 8.15 Deformation modes on a sheet blank during forming operations....
16. Figure 8.16 Variation of the FLD with temperature. (a) For 5754 alloy and ...
17. Figure 8.17 Measurements of deformation by using the grid technology.
18. Figure 8.18 A 2D axial‐symmetric finite element model.
19. Figure 8.19 Temperature distributions on the blank surface (a) RT, (b) 200...
20. Figure 8.20 (a) Finite element modeling of the hemispherical dome test and...
21. Figure 8.21 (a) Thickness strains vs. blank length at various temperatures...
22. Figure 8.22 Experimental vs. predicted values for softening model. (a) Sof...
23. Figure 8.23 Comparison of experiments and the softening model.
Chapter 9
1. Figure 9.1 Warm sheet hydroforming with die.
2. Figure 9.2 Warm hydromechanical deep drawing process (Warm HMD).
3. Figure 9.3 Warm hydroforming parameters [7].
4. Figure 9.4 Controllable process variables and control strategies [11].
5. Figure 9.5 Three different thermal models at low forming speed: (a) isothe...
6. Figure 9.6 The necessary fluid pressure according to the material, the thi...
7. Figure 9.7 Optimized fluid pressure and blank holder force paths obtained ...
8. Figure 9.8 Process windows for hydraulic pressure and blank holder force a...
9. Figure 9.9 Schematic representation of warm tube hydroforming steps [24]....
10. Figure 9.10 Friction zones in tube hydroforming for T‐shape [26].
11. Figure 9.11 (a) Warm hydroforming setup with nonuniform temperature fields...
12. Figure 9.12 Integration of heating system to a warm tube hydroforming setu...
13. Figure 9.13 Hot bulge testing equipment developed by Elsenheimer and Groch...
14. Figure 9.14 Warm tube hydroforming setup used by Hashemi et al. [28].
15. Figure 9.15 Results with optimum profile (a) FEA, (b) experimental, and (c...
16. Figure 9.16 Verification of critical damage value obtained with the develo...
Chapter 10
1. Figure 10.1 Temperature ranges for forming processes.
2. Figure 10.2 Steel grades.
3. Figure 10.3 A typical middle‐class car body with typical hot stamping part...
4. Figure 10.4 Hot stamping applications in automotive industry. (a) Bumper, ...
5. Figure 10.5 A hot stamping part made from DP steel in an auto body.
6. Figure 10.6 Hot stamped front windshield beam member.
7. Figure 10.7 V‐shaped cold and hot‐formed tubes using resistance heating: (...
8. Figure 10.8 Basic hot stamping process chains: (a) direct and (b) indirect...
9. Figure 10.9 Hot stamping on steel material.
10. Figure 10.10 Influence of forming temperature on the flow stress.
11. Figure 10.11 Usage of Al–Si alloying layer as a lubricant and oxidation pr...
12. Figure 10.12 Schematic representation of the process sequence in relation ...
13. Figure 10.13 A conventional laboratory scaled heating furnace.
14. Figure 10.14 A laboratory‐scaled electric conduction heating system.
15. Figure 10.15 An illustration of the induction heating system.
16. Figure 10.16 TTT‐diagram of 22MnB5.
17. Figure 10.17 Relationships between final load and final reduction in thick...
18. Figure 10.18 A resistance heating developed and local resistance heating o...
19. Figure 10.19 Main thermomechanical‐phase transformation trilogy in hot sta...
20. Figure 10.20 An isothermal FE analysis result.
21. Figure 10.21 Cast conformable cooling channels.
22. Figure 10.22 A new trend on the tool design in hot stamping.
23. Figure 10.23 Comparison of contact surface after loading and unloading (a)...
24. Figure 10.24 In one product, both ductility and increased yields can be de...
25. Figure 10.25 The deformation history of the front side rail using (a) simp...
26. Figure 10.26 TWBs of low alloy high strength steel and boron steel.
27. Figure 10.27 Deformations on TWBs.
28. Figure 10.28 New and alternative heating concepts.
Chapter 11
1. Figure 11.1 Example of enhanced formability in electromagnetic forming (EM...
2. Figure 11.2 Variations on electromagnetic forming (a) compression, (b) exp...
3. Figure 11.3 Schematic diagram of MPW process [7].
4. Figure 11.4 Wavy pattern observed at the interface during MPW [9].
5. Figure 11.5 Current trace from a capacitor bank discharge measured using a...
6. Figure 11.6 Formed components using a flat spiral coil showing nonsymmetri...
7. Figure 11.7 Pictures of (a) a uniform pressure actuator coil and (b) entir...
8. Figure 11.8 Coil design with two halves [16].
9. Figure 11.9 Schematic representation of EMF used to create a local feature...
10. Figure 11.10 Example MPW components from (a) Ford, (b) Xerox and (c) Johns...
11. Figure 11.11 Equipment used for MPW: (a) Capacitor Bank and forming chambe...
12. Figure 11.12 Comparison between (a) conventionally and (b) electromagnetic...
13. Figure 11.13 Schematics and photographs of EHF chambers for free bulging a...
14. Figure 11.14 Pressure pulses generated by 12‐KJ energy release at various ...
15. Figure 11.15 Aluminum tube formed with different techniques: (a) EHF witho...
16. Figure 11.16 Components formed electrohydraulically from (a) aluminum and ...
17. Figure 11.17 Electrohydraulic forming machines. (a) Cincinnati Electroshap...
18. Figure 11.18 Schematic representation of an explosive‐forming process.
19. Figure 11.19 (a) Schematic representation of vaporizing foil actuator weld...
20. Figure 11.20 Schematic diagram of laser impact welding process.
21. Figure 11.21 Velocities measured using PDV system during electromagnetic t...
22. Figure 11.22 Comparison of velocities measured using PDV and a fibre optic...
23. Figure 11.23 Schematic representation of laser sheet and photodiode detect...
24. Figure 11.24 High‐speed imaging (Every 30 0039Cs) of an electromagnetic fo...
25. Figure 11.25 Schematic diagram of a split Hopkinson tension bar (Aka Kolsk...
26. Figure 11.26 (a) Schematic representation of the experimental setup, inclu...
27. Figure 11.27 Comparison between (a) experiments and (b) loosely coupled FE...
28. Figure 11.28 Workpiece velocity with varying workpiece conductivity and an...
29. Figure 11.29 Wavy patterns in (a) cloud formations [6], (b) MPW [2], and (...
Chapter 12
1. Figure 12.1 Example of sculptured surfaces by HSM.
2. Figure 12.2 Vertical machine tool.
3. Figure 12.3 Cutting edge radius of micro end mill tool.
4. Figure 12.4 High‐speed milling under cooling conditions.
5. Figure 12.5 Motor block by milling.
6. Figure 12.6 Example of mold cavity.
7. Figure 12.7 High‐speed milling using a micro end mill tool of 200 μm.
Chapter 13
1. Figure 13.1 Common tool geometries.
2. Figure 13.2 Saw‐tooth shape chip formation in machining hardened steel....
3. Figure 13.3 Examples of surface defects in machining.
4. Figure 13.4 Example of microhardness profile and machining‐affected zone....
5. Figure 13.5 Typical residual stress profile.
Chapter 14
1. Figure 14.1 Flow stress distributions for different strain, strain rate, a...
2. Figure 14.2 Stage of the ductile fracture: (a) void initiation, (b) void g...
3. Figure 14.3 Critical damage value evaluation using FE analysis.
4. Figure 14.4 Coulomb law limited by the shear strength value.
5. Figure 14.5 Frictional stress vs. normal stress distributions obtained uti...
6. Figure 14.6 Orthogonal cutting simulations result for a tool rake angle of...
7. Figure 14.7 Simulated plastic, shearing, and fracture stages during the bl...
8. Figure 14.8 Simulation of first, second, and third pass of the produced pa...
9. Figure 14.9 Surface cracking defect: experiment (a) and simulation (b) com...
10. Figure 14.10 Die material hardness as function of the temperature.
11. Figure 14.11 Schematic of the hot forming process.
12. Figure 14.12 Comparison between simulated (squares) and actual (continuous...
13. Figure 14.13 The flow stress curves of the surface and internal grains....
14. Figure 14.14 (a) 3D simulation of preform for a microaxle, and (b) the exp...
15. Figure 14.15 Example of the extruded micropin.
16. Figure 14.16 (a) Grain distribution in microextrusion and (b) results.
17. Figure 14.17 (a) Methodology flow chart and (b) deflection direction limit...
18. Figure 14.18 Comparison between simulative and theoretical models.
Chapter 15
1. Figure 15.1 The microstructure of microcrystalline aluminum oxide grits in...
2. Figure 15.2 The new classification of grinding wheel conditioning.
3. Figure 15.3 With sharpening of the grinding wheels after profiling, the ch...
4. Figure 15.4 Different methods of grinding wheel profiling by stationary an...
5. Figure 15.5 The conventional diamond dresser consist of numerous diamond g...
6. Figure 15.6 After dressing by T‐Dress, the forms of the grinding wheel abr...
7. Figure 15.7 The laser beam can be irradiated (a) radially or (b) tangentia...
8. Figure 15.8 Schematic representation of ELID dressing process.
9. Figure 15.9 Generation of different structures on the grinding wheels to o...
10. Figure 15.10 Application of laser beam to make microstructures and macrost...
11. Figure 15.11 Schematic representation of the innovative T‐Tool. With this ...
12. Figure 15.12 The results of plunge cylindrical grinding with structured an...
13. Figure 15.13 The maximum temperature rise vs. the depth “z” in grinding of...
14. Figure 15.14 The workpiece surface temperature as a function of wheel spee...
15. Figure 15.15 Effect of workpiece speed and specific removal rate on surfac...
16. Figure 15.16 Schematic illustration of the ultrasonic systems (a) the conv...
17. Figure 15.17 Workpiece temperature is reduced when employing ultrasonic vi...
18. Figure 15.18 Schematic representation of the ultrasonic dressing system fo...
19. Figure 15.19 Effects of ultrasonic‐assisted dressing on the grinding and d...
Chapter 16
1. Figure 16.1 Principle of the EDM process showing the gap phenomena and res...
2. Figure 16.2 Schematic diagram showing different units of the EDM system.
3. Figure 16.3 Schematic representation of (a) RC type and (b) transistor‐typ...
4. Figure 16.4 The ideal voltage–time and current–time characteristics curve ...
5. Figure 16.5 Principle of servo control system based on ignition delay.
6. Figure 16.6 Different types of pulses generated during the EDM process....
7. Figure 16.7 Schematic diagram showing the principle of die‐sinking EDM....
8. Figure 16.8 Application examples of die‐sinking EDM: (a) die for mobile ph...
9. Figure 16.9 Schematic diagram showing the working principle of the wire‐ED...
10. Figure 16.10 Application examples of wire EDM: (a) complex molds for injec...
11. Figure 16.11 Schematic showing the principle of milling EDM [34].
12. Figure 16.12 Application examples of EDM milling: (a) micropyramids produc...
13. Figure 16.13 EDM drilling process: (a) fabrication of electrode using wire...
14. Figure 16.14 Application examples of EDM and micro‐EDM drilling: (a) 6.5‐μ...
15. Figure 16.15 Schematic diagrams showing the working principle of rotary di...
16. Figure 16.16 Application examples of RDE‐EDM; (a) scanning electron micros...
17. Figure 16.17 Schematic diagram showing the working principle of the dry ED...
18. Figure 16.18 Application examples of dry EDM milling in machining of spher...
19. Figure 16.19 Schematic diagram showing the working principle of planetary ...
20. Figure 16.20 Application examples of planetary EDM; (a) blind cavities fab...
21. Figure 16.21 Schematic representation of fabricating microelectrode using ...
22. Figure 16.22 Application examples of reverse EDM/micro‐EDM: (a) arrays of ...
23. Figure 16.23 (a) Principle of abrasive electrical discharge grinding (AEDG...
24. Figure 16.24 (a) Comparison of the MRR between grinding as a single proces...
25. Figure 16.25 (a) AWEDM: combination of EDM with an abrasive process; (b) c...
26. Figure 16.26 Schematic diagram showing the comparison of working principle...
27. Figure 16.27 Fabrication of mold cavity (a) without and (b) with the powde...
28. Figure 16.28 (a) Mechanism of applying vibration to the tool electrode. (b...
29. Figure 16.29 Microfeatures machined by vibration‐assisted micro‐EDM; (a) m...
30. Figure 16.30 Mechanism of EDM–ECM combined process showing the discharging...
31. Figure 16.31 (a) Surface generated by EDM; (b) surface generated by ECM fo...
32. Figure 16.32 Schematic representation of the magnetic field–assisted EDM....
33. Figure 16.33 (A) Comparison of MRR between conventional and magnetic force...
34. Figure 16.34 (a) Pin and plate microassembly by micro‐EDM and laser weldin...
35. Figure 16.35 Machining examples of dry nano‐EM: (a) machining of “NSF” usi...
Chapter 17
1. Figure 17.1 Ultraprecision machine tools for micromilling: (a) Kern micro ...
2. Figure 17.2 MQL with low‐volume sprays of oil delivered in compressed air:...
3. Figure 17.3 Machining using an edge radius tool.
4. Figure 17.4 Formation of the chip above and below the MUCT: (a) depth of c...
5. Figure 17.5 Surface profile and projected area of the conical tool.
6. Figure 17.6 Chip thickness model considering elastic recovery.
7. Figure 17.7 Ploughing area and elastic recovery.
8. Figure 17.8 Comparison of forces between the simulation and KF compensated...
9. Figure 17.9 Receptance coupling of a spindle and an arbitrary end mill....
10. Figure 17.10 Tool tip dynamics using the RC Method.
11. Figure 17.11 Wavy surface and phase shift in machining.
12. Figure 17.12 Comparison of micromilling stability lobes with conventional ...
Chapter 18
1. Figure 18.1 Laser material interaction. (a) Heating, (b) surface melting, ...
2. Figure 18.2 Multiscan microchannels ablated with a femtosecond laser in (a...
3. Figure 18.3 Microgroove of aluminum titanate machined with an Nd:YAG laser...
4. Figure 18.4 Laser ablation with (a) nanosecond pulse, (b) picosecond pulse...
5. Figure 18.5 Relationship between wavelength and transmission for some mate...
6. Figure 18.6 Laser drilling approaches.
7. Figure 18.7 Longitudinal cross‐sections of laser‐drilled hole in (a) 4‐mm ...
8. Figure 18.8 SEM images of picoseconds laser cutting of stents (a) nitinol,...
9. Figure 18.9 Schematic illustration of the laser milling process.
10. Figure 18.10 Images of microchannels.
Chapter 19
1. Figure 19.1 Plasma generating scheme.
2. Figure 19.2 PEM setup configuration.
3. Figure 19.3 Flank wear in conventional vs. PEM (a _p = 3.175 mm, a _e = 4 ...
4. Figure 19.4 Strain hardening in Haynes 25 after plasma assisted milling (P...
5. Figure 19.5 Energy absorption for different materials.
6. Figure 19.6 Beam quality for different laser sources.
7. Figure 19.7 Laser orientation in LAM. (a) Normal to workpiece and (b) norm...
8. Figure 19.8 Total cost comparison for LAM and conventional machining.
9. Figure 19.9 Wear evolution with temperature in Inconel 718 machining.
10. Figure 19.10 Gain switching–based surface texturing.
11. Figure 19.11 Q‐switching–based surface modification.
12. Figure 19.12 Active mode locking.
13. Figure 19.13 Passive mode locking.
14. Figure 19.14 Direct laser and conventional machining combination.
15. Figure 19.15 Temperature and tensile strength relation for different metal...
16. Figure 19.16 Difference between linear source and point source.
17. Figure 19.17 Energy distribution in laser beam considering the beam parame...
18. Figure 19.18 Laser‐assisted dressing: Process configuration (a) and dressi...
19. Figure 19.19 Laser‐assisted ball burnishing: Process configuration (a) and...
Chapter 20
1. Figure 20.1 Basic components of an SLS machine: (1) computer; (2) laser; (...
2. Figure 20.2 Solid‐state sintering neck formation.
3. Figure 20.3 Factors that affect the laser sintering process.
4. Figure 20.4 Examples of scan patterns, (a) sorted in X‐direction; (b) sort...
5. Figure 20.5 Staircase effect.
6. Figure 20.6 Reflection from powder particles.

List of Contributors

Isabel Bagudanch
Departament d’Enginyeria Mecànica i de la Construcció Industrial
EPS – Universitat de Girona

c/M. Aurèlia CapmanyGirona 17003, Spain
Mustafa Bakkal
Faculty of Mechanical Engineering
Istanbul Technical University

Istanbul, Turkey
Elisabetta Ceretti
Department of Mechanical and Industrial Engineering
University of Brescia

Via Branze 38, 25123 Brescia, Italy
Joaquim Ciurana
Department of Mechanical Engineering and Industrial Construction, Product Process and Production Engineering Research Group
School of Engineering, University of Girona

Girona, Spain
Ömer N. Cora
Department of Mechanical Engineering
Karadeniz Technical University

Trabzon, Turkey
Luis Criales
Manufacturing and Automation Research Laboratory, Department of Industrial and Systems Engineering
School of Engineering, Rutgers University

Piscataway, NJ 08854, USA
Amir Daneshi
Institute of Grinding and Precision Technology (KSF)
Hochschule Furtwangen University

Furtwangen im Schwarzwald, Germany
Jordi Delgado
Department of Mechanical Engineering and Industrial Construction, Product Process and Production Engineering Research Group
School of Engineering, University of Girona

Girona, Spain
Asier Fernández
Department of Mechanical Engineering
University of Basque Country UPV/EHU

Bilbao, Spain
Inés Ferrer
Department of Mechanical Engineering and Industrial Construction
University of Girona

Girona, Spain
Antonio Fiorentino
Department of Mechanical and Industrial Engineering
University of Brescia

Via Branze 38, 25123 Brescia, Italy
Gerardo García
Center for Innovation in Design and Technology
Tecnológico de Monterrey

Monterrey, México
Maria Luisa Garcia‐Romeu
Departament d’Enginyeria Mecànica i de la Construcció Industrial
EPS – Universitat de Girona

c/M. Aurèlia CapmanyGirona 17003, Spain
Claudio Giardini
Department of Engineering
University of Bergamo

Via Pasubio 7b24044 Dalmine (Bg), Italy
Hüseyin S. Halkacı
Department of Mechanical Engineering
Konya Technical University

Konya, Turkey
MK‐C Hartl
Muhammad P. Jahan
Department of Mechanical and Manufacturing Engineering
Miami University

Oxford, OH 45056, USA
Martin B.G. Jun
School of Mechanical Engineering
Purdue University

585 Purdue Mall, West LafayetteIN 47907, USA
Ilyas Kacar
Department of Mechatronics Engineering
Nigde Omer Halisdemir University

Nigde, Turkey
Umut Karagüzel
Mechanical Engineering Department
Isik University

Istanbul, Turkey
Brad Kinsey
Muammer Koç
College of Science and Engineering, Divison of Sustainable Development
Hamad Bin Khalifa University

Doha, Qatar
Yannis Korkolis
Ali T. Kuzu
Faculty of Mechanical Engineering
Yeditepe University

Istanbul, Turkey
Aitzol Lamikiz
Department of Mechanical Engineering
University of Basque Country UPV/EHU

Bilbao, Spain
Silvia Martínez
Department of Mechanical Engineering
University of Basque Country UPV/EHU

Bilbao, Spain
Karla Monroy
Department of Mechanical Engineering and Industrial Construction, Product Process and Production Engineering Research Group
School of Engineering, University of Girona

Girona, Spain
Tuğrul Özel
Manufacturing and Automation Research Laboratory, Department of Industrial and Systems Engineering
School of Engineering, Rutgers University

Piscataway, NJ 08854, USA
Fahrettin Ozturk
Department of Mechanical Engineering
Ankara Yıldırım Beyazıt University

Ankara, Turkey
and
Strategy and Technology Management
Turkish Aerospace Industries Inc.

Ankara, Turkey
Simon S. Park
Department of Mechanical and Manufacturing Engineering
University of Calgary

Calgary, Alberta, Canada
Rogelio Pérez‐Santiago
Department of Industrial and Mechanical Engineering
Universidad de las Americas Puebla

Cholula, Mexico
Guillem Quintana
ASCAMM Technology Centre
Barcelona, Spain
Lidia Serenó
Department of Mechanical Engineering and Industrial Construction, Product Process and Production Engineering Research Group
School of Engineering, University of Girona

Girona, Spain
Ivan Tabernero
Department of Mechanical Engineering
University of Basque Country UPV/EHU

Bilbao, Spain
Taghi Tawakoli
Institute of Grinding and Precision Technology (KSF)
Hochschule Furtwangen University

Furtwangen im Schwarzwald, Germany
Dani Teixidor
Department of Mechanical Engineering and Industrial Construction
University of Girona

Girona, Spain
Serkan Toros
Department of Mechanical Engineering
Nigde Omer Halisdemir University

Nigde, Turkey
Mevlüt Türköz
Department of Mechanical Engineering
Konya Technical University

Konya, Turkey
Eneko Ukar
Department of Mechanical Engineering
University of Basque Country UPV/EHU

Bilbao, Spain
Durul Ulutan
Manufacturing and Automation Research Laboratory, Department of Industrial and Systems Engineering
School of Engineering, Rutgers University

Piscataway, NJ 08854, USA
Rahmi Ünal
Mechanical Engineering Department
Gazi University

Ankara, Turkey
Elisa Vázquez
Department of Mechanical Engineering and Civil Construction
Universitat de Girona

Girona, Spain
Minjie Wang
School of Mechanical Engineering
Dalian University of Technology

Dalian, PR China
Donggang Yao
School of Materials Science and Engineering
Georgia Institute of Technology

Atlanta, GA, USA
Danyang Zhao
School of Mechanical Engineering
Dalian University of Technology

Dalian, PR China
and
School of Materials Science and Engineering
Georgia Institute of Technology

Atlanta, GA, USA

Modern Manufacturing Processes

Copyright

Foreword

List of Contributors

Part I
Advanced Forming Processes