Advanced Manufacturing and Processing Technology (Manufacturing Design and Technology)

"This book disseminates recent research, theories, and practices relevant to areas of surface engineering and processing of materials for functional application such as aerospace, automobile, and biomedical. The book focuses on the hidden technologies and advanced manufacturing methods which may not be standardized by the research fraternity, however, are greatly beneficial to the material and manufacturing industrial engineers in different aspects. It provides such projects, research activities, and innovations on a global platform to strengthen the knowledge of the concerned community. The book covers surface engineering including coating, deposition, cladding, nanotechnology, surface finishing, precision machining, processing, and emerging advanced manufacturing technologies to enhance the performance of materials in terms of corrosion, wear and fatigue. The book has capture emerging areas of materials science and advanced manufacturing engineering and presents the recent trends in research for young researchers, field engineers, and academic professionals"-- Provided by publisher The goal of this book is to provide technical insights on recent innovations in the different classes of advanced manufacturing and processing technologies available in modern manufacturing sectors. Cover 1 Half Title 2 Series Page 3 Title Page 4 Copyright Page 5 Table of Contents 6 Preface 8 Editors 10 Contributors 12 Chapter 1 A Critical Review on the Machining of Engineering Materials by Die-Sinking EDM 14 1.1 Introduction 14 1.2 Researches on Electrical Discharge Machining Process 15 1.2.1 Researches on Enhancement of Tool Wear 15 1.2.2 Optimization of Process Parameters 16 1.2.3 Selection of Electrode Material 17 1.2.4 Multispark Erosion Studies 19 1.2.5 Selection of Optimized Pulse Duration 20 1.2.6 Vibratory Tool and Workpiece 21 1.2.7 Introducing Servo Control Mechanism 22 1.2.8 Magnetic Field–Based Electrical Discharge Machining 22 1.2.9 Special Tools 23 1.2.10 CNC-Controlled Electrical Discharge Machining 24 1.2.11 Selection of Dielectric Medium 24 1.3 Application of Electrical Discharge Machining for Biomaterials 26 1.4 Conclusions 26 References 27 Chapter 2 Optimization of Machining Parameters of High-Speed Toolpath to Achieve Minimum Cycle Time for Ti-6Al-4V 36 2.1 Introduction to High-SpeedMachining 37 2.2 Experimental Setup 39 2.2.1 Selection of Material 39 2.2.2 Job Setup on Machine 39 2.2.3 Machine Specifications 41 2.2.4 High Helix Cutter 41 2.2.5 Machining Strategy: Dynamic Cutting Strategy from Mastercam Software 42 2.2.6 Selection of Parameters 43 2.2.7 Design of Experimentation 44 2.2.8 Results from Response Surface Methodology 44 2.3 Results and Discussions 46 2.3.1 Effect of Process Parameters on the Spindle Load 47 2.3.2 Effect of the Process Parameters on Cycle Time 50 2.4 Conclusion 54 References 56 Chapter 3 A Review of Machinability Aspects of Difficult-to-Cut Materials Using Microtexture Patterns 58 3.1 Introduction 59 3.1.1 Judging Machinability 60 3.1.1.1 Tool Life 60 3.1.1.2 Power Consumption 60 3.1.1.3 Surface Finish 60 3.1.1.4 Chip Form 61 3.1.2 Difficult-to-Cut Material 62 3.1.3 Compilation of Machining Technologies 62 3.1.4 Various Steps Taken to Solve Issues 63 3.1.4.1 Hot Machining 63 3.1.4.2 Minimum Quantity of Lubricant 64 3.1.4.3 Coated Tools 64 3.1.4.4 High-SpeedMachining 65 3.1.4.5 Flood Cooling 66 3.1.4.6 Microgrooves 66 3.2 Literature Review 67 3.3 Discussion and Future Work 74 3.4 Conclusions 75 References 75 Chapter 4 Micromachining 80 4.1 Introduction 81 4.2 Conventional Micromachining 82 4.3 Nonconventional Micromachining 84 4.3.1 Ultrasonic Micromachining 80 4.3.1.1 Working Principle 84 4.3.1.2 Tool Material 84 4.3.1.3 Tool Feed Mechanism 85 4.3.1.4 Abrasive Slurry System 85 4.3.1.5 Oscillating System 85 4.3.1.6 Process Parameters 86 4.3.1.7 Effect of Process Parameters on Material Removal Rate 86 4.3.1.8 Advantages 87 4.3.1.9 Limitations 87 4.3.1.10 Applications 87 4.3.2 Abrasive Jet Micromachining 87 4.3.2.1 Working Principle 88 4.3.2.2 Process Parameters 88 4.3.2.3 Abrasive Material 89 4.3.2.4 Gas Medium 90 4.3.2.5 Nozzle 90 4.3.2.6 Effect of Material Removal Rate 90 4.3.2.7 Advantages 90 4.3.2.8 Limitations 90 4.3.2.9 Applications 91 4.3.3 Electrochemical Micromachining 91 4.3.3.1 Working Principle 91 4.3.3.2 Process Parameters 92 4.3.3.3 General Material Removal Rate Model for Electrochemical Micromachining 94 4.3.3.4 Advantages 95 4.3.3.5 Limitations 95 4.3.3.6 Applications 95 4.3.4 Electrodischarge Micromachining 96 4.3.4.1 Working Principle 96 4.3.4.2 Components of Electrodischarge Micromachining 97 4.3.4.3 Process Parameters 98 4.3.4.4 Variants of Electrodischarge Micromachining 98 4.3.4.5 Advantages 99 4.3.4.6 Limitations 100 4.3.4.7 Applications 100 4.3.5 Laser Beam Micromachining 101 4.3.5.1 Working Principle 101 4.3.5.2 Mechanism of Material Removal 102 4.3.5.3 Laser Mask Projection Technique 104 4.3.5.4 Effect of Laser Beam Intensity 104 4.3.5.5 Material Removal Rate in Pulsed Laser 105 4.3.5.6 Advantages 107 4.3.5.7 Limitations 107 4.3.5.8 Applications 107 4.3.6 Electron Beam Micromachining 108 4.3.6.1 Working Principle 108 4.3.6.2 Electron Beam Micromachining Equipment 109 4.3.6.3 Components of Electron Beam Micromachining 109 4.3.6.4 Process Parameters 111 4.3.6.5 Advantages 112 4.3.6.6 Limitations 112 4.3.6.7 Applications 113 4.3.7 Plasma Arc Micromachining 113 4.3.7.1 Working Principle 114 4.3.7.2 Process Parameter 114 4.3.7.3 Advantages 115 4.3.7.4 Limitations 115 4.3.7.5 Applications 115 4.4 Conclusions and Future Study 115 References 118 Chapter 5 A Review Study on Miniaturization—A Boon or Curse 124 5.1 Introduction 124 5.2 Recent Studies 126 5.2.1 Process Physics 126 5.2.2 Minimum Chip Thickness and Specific Cutting Energy 128 5.2.3 Ductile Mode Machining 129 5.2.4 Edges and Surface Finish 130 5.2.5 Workpiece and Design Issues 132 5.2.6 Machines, Tools, and Systems for Micromachining 132 5.2.7 Cutting Fluid 133 5.2.8 Machine Components and Controls 135 5.2.9 Metrology in Micromachining 136 5.3 Conclusion and Brief Discussion 138 5.4 Future Scope 138 References 139 Chapter 6 A Comprehensive Review on Similar and Dissimilar Metal Joints by Friction Welding 146 6.1 Introduction 146 6.2 Friction Welding between Ferrous and Nonferrous Metal Alloys 147 6.3 Friction Welding between Ferrous Metal Alloys 148 6.4 Friction Welding between Nonferrous Metal Alloys 154 6.5 Finite Element Model in Friction Welding 155 6.6 Conclusion 156 References 157 Chapter 7 3D Bioprinting in Pharmaceuticals, Medicine, and Tissue Engineering Applications 160 7.1 Introduction 161 7.2 3D Printing in Pharmaceuticals 163 7.3 3D Printing in Medicine 165 7.3.1 Materials 165 7.3.2 In situ 3D Bioprinting 166 7.3.2.1 Biomimicry 167 7.3.2.2 Independent Self-Assembly 167 7.3.2.3 Miniature Tissue Blocks 168 7.3.3 Bioscaffolding 168 7.4 Conclusion 170 References 170 Chapter 8 Investigating on the Lapping and Polishing Process of Cylindrical Rollers 176 8.1 Introduction 177 8.2 Fundamental Principle 177 8.3 Experimental Models to Determine Friction Coefficient in Machining 178 8.3.1 Setup and Conditions for Lapping Process 178 8.3.2 Setup and Conditions for Polishing Process 179 8.4 Effects of Experimental Conditions on the Friction Coefficients 179 8.4.1 Lapping Process with SiC Abrasive Slurry 179 8.4.2 Polishing Process with Al(2)O(3) Abrasive Slurry 182 8.5 Experimental Results for Lapping Process 185 8.5.1 Experimental Setup 185 8.5.2 Effect of Abrasive Size to Surface Roughness of Cylindrical Roller 186 8.5.3 Effect of Downforce to Surface Roughness of Cylindrical Roller 186 8.5.4 Effect of Downforce to Material Removal Rate of Cylindrical Roller 188 8.5.5 Effect of Downforce to Roundness of Cylindrical Roller 188 8.6 Experimental Results for Polishing Process 190 8.6.1 Experimental Setup 190 8.6.2 Effect of Abrasive Size to Surface Roughnessof Cylindrical Roller 190 8.6.3 Effect of Downforce to Surface Roughness of Cylindrical Roller 191 8.6.4 Effect of Downforce to Material Removal Rate of Cylindrical Roller 191 8.6.5 Effect of Downforce to Roundness of Cylindrical Roller 193 8.7 Conclusion 195 References 196 Chapter 9 NiTi Thin-Film Shape Memory Alloys and Their Industrial Application 198 9.1 Historical Background of Shape Memory Alloys 198 9.2 What Is Unique about NiTi Alloy? 200 9.3 Stress–Strain–Temperature Curve of a NiTi 200 9.4 Physical Metallurgy of NiTi Thin Film 201 9.4.1 Phase Diagram 201 9.4.2 Martensitic Transformation and Crystallography 204 9.5 Physical Properties of the NiTi Thin Film 207 9.5.1 Field-EmissionScanning Electron Microscopy 207 9.5.2 Grazing Incidence X-RayDiffraction 209 9.5.3 High- Resolution Transmission Electron Microscopy 210 9.6 Applications of Shape Memory Alloys 213 9.6.1 Microvalves and Micropumps 214 9.6.2 Microgripper and Microtweezer 215 9.6.3 Biomedical Equipment 215 9.7 Advantages and Limitations of NiTi Thin Film 215 9.8 Conclusions 217 References 217 10 Carbon Fibers: Surface Modification Strategies and Biomedical Applications 220 10.1 Surface Treatment 220 10.1.1 Surface Oxidation 221 10.1.2 Surface Coating 223 10.2 Applications of Carbon Fibers 225 10.2.1 Carbon Fibers and Composite Implant for Bone 226 10.2.2 Carbon Fiber in Tissue Growth 226 10.2.3 Dental Implants 227 10.2.4 Regenerative Medicine 227 10.2.5 Carbon Fibers in Drug Delivery 228 10.2.6 Carbon Fibers in Biomedical Sensor 229 10.2.7 Carbon Fibers Composites 230 10.3 Summary 232 References 233 Index 238 Machining,Parameters;,High-Speed,Toolpath;,Micromachining;,3D,Bioprinting;,Carbon,Fibers Machining Parameters,High-Speed Toolpath,Micromachining,3D Bioprinting,Carbon Fibers This book disseminates recent research, theories, and practices relevant to the areas of surface engineering and the processing of materials for functional applications in the aerospace, automobile, and biomedical industries. The book focuses on the hidden technologies and advanced manufacturing methods that may not be standardized by research institutions but are greatly beneficial to material and manufacturing industrial engineers inmany ways. It details projects, research activities, and innovations in a global platform to strengthen the knowledge of the concerned community. The book covers surface engineering including coating, deposition, cladding, nanotechnology, surface finishing, precision machining, processing, and emerging advanced manufacturing technologies to enhance the performance of materials in terms of corrosion, wear, and fatigue. The book captures the emerging areas of materials science and advanced manufacturing engineering and presents recent trends in research for researchers, field engineers, and academic professionals