The relative motion between the tool and the workpiece during cutting compresses the work material near the tool and induces a shear deformation that forms the chip. This article discusses the fundamental nature of the deformation process associated with machining. It describes the mechanics of the machining process, and presents the principles of the orthogonal cutting model. The article also analyzes the effect of workpiece properties on chip formation.

This article describes the basic concepts of the complex factors that influence the forces, power, and stresses in machining. It provides an overview of the models of orthogonal (that is, two force) machining of metals as they are useful for understanding the basic mechanics of machining and can be extended for modeling of the production processes. The article discusses stresses on the shear plane, stresses distributions on the rake face, uniform stresses on the rake face, and nonuniform stress distributions on the rake face. It also examines the specific power consumption in turning, drilling, and milling operations. The article concludes with a section on the factors affecting specific power.

This article addresses problems, such as “in spec” dilemma and on-target key, associated with traditional approaches to quality. It discusses major robust design techniques, tools, and concepts, such as quality loss function, parameter design, tolerance design, signal-to-noise ratio, technology development, and orthogonal arrays.

This article begins with information on the fundamentals of chip formation process and general considerations for the modeling and simulation of machining processes. It focuses on smaller-scale models that seek to characterize the workpiece/tool/chip interface and behaviors closely associated with that. The article describes the advantages and disadvantages of various finite-element modeling approaches, namely, transient models, continuous cutting model, steady-state model, hybrid model, two-dimensional models, and three-dimensional models. It discusses flow stress measurements using constitutive and inverse testing methods and reviews tool design for chip removal. The article explains the effect of tool geometry on burr formation and the effect of coatings on tool temperatures. It concludes with information on tool wear, which is an unavoidable effect of metal cutting.

Machining tribology poses a significant challenge due to the multiple parameters that must be simultaneously considered to arrive at a cost-minimized solution in production. This article provides information required to make informed decisions about machining parameters. It describes the relationships between machining parameters, workpiece material properties, cutting forces, and the corresponding temperature field in the chip. The article provides information on tool life, with an empirical model, common wear features, and the relationship between tool life and machining cost. The cutting fluids and their effect on tool life are also discussed. The article discusses machining process dynamics and corresponding vibrations. It contains a table that provides a summary of high-pressure coolant research.

This article discusses the mechanics of chip formation and reviews the analytical modeling of the chip formation process by high-speed machining within the framework of continuum mechanics. It examines the relationship between the various high-speed machining parameters. The article describes the cutting tool systems for aluminum alloys, steel, superalloys, and titanium alloys and provides an overview of the alternative cutting tool geometries for increasing tool life. It highlights the factors considered by companies planning to employ high-speed machining systems and concludes with information on the applications of high-speed machining.

Fundamental to the machining process, is the metal-cutting operation, which involves extensive plastic deformation of the work piece ahead of the tool tip, high temperatures, and severe frictional conditions at the interfaces of the tool, chip, and work piece. This article explains that the basic mechanism of chip formation is shear deformation, which is controlled by work material properties such as yield strength, shear strength, friction behavior, hardness, and ductility. It describes various chip types, as well as the cutting parameters that influence chip formation. It also demonstrates how the service life of cutting tools is determined by a number of wear processes, including tool wear, machining parameters, and tool force and power requirements. It concludes by presenting a comprehensive collection of formulas for turning, milling, drilling, and broaching, and its average unit power requirement.

Additive manufacturing (AM) offers expansive design freedoms for realizing parts that are more complex and customized than their conventionally fabricated counterparts, but all AM technologies impose restrictions on buildable geometries and features. Design rules capture those restrictions in the form of best practices to successfully design for AM. This article discusses how design rules can potentially support and accelerate the process of developing part geometry for AM. The discussion provides examples of design rules that are independent of any specific AM process and then discusses design rules specific to particular AM processes.

This article describes the types of fabrics and preforms used in the manufacture of advanced composites and related selection, design, manufacturing, and performance considerations. The types of fabrics and preforms include unidirectional and two-directional fabrics; multidirectionally reinforced fabrics; hybrid fabrics; woven fabric prepregs; unidirectional and multidirectional tape prepregs; and the prepreg tow. The article discusses three major categories of tape manufacturing processes, namely, the hand lay-up, machine-cut patterns that are laid up by hand, and the automatic machine lay-up. It provides a description of the two classes of prepregs. These include those that are suitable for high-performance applications and suitable for lower-performance molding compounds.

A major cause of failure in components subjected to rolling or rolling/sliding contacts is contact fatigue. This article focuses on the rolling contact fatigue (RCF) performance and failure modes of overlay coatings such as those deposited by physical vapor deposition, chemical vapor deposition, and thermal spraying (TS). It provides a background to RCF in bearing steels in order to develop an understanding of failure modes in overlay coatings. The article describes the underpinning failure mechanisms of TiN and diamond-like carbon coatings. It presents an insight into the design considerations of coating-substrate material properties, coating thickness, and coating processes to combat RCF failure in TS coatings.

Braiding is a textile process that is known for its simplicity and versatility. Braided structures are unique in their high level of conformability, torsional stability, and damage resistance. This article describes the braiding process and the mechanical properties of two-dimensional and three-dimensional braiding.

This article provides a discussion on ten rules for the effective production of reliable castings. These rules include good-quality melt, liquid front damage, liquid front stop, bubble damage, core blows, shrinkage damage, convection damage, segregation, residual stress, and location points.

This article presents an approach to manage the uncertainty present in materials design. It describes inductive and deductive approaches to deal with uncertainty. The article focuses on providing an understanding of the opportunities for managing uncertainty and the decisions that influence the accuracy of the results. A design of experiments (DOE) represents a sequence of experiments to be performed, expressed in terms of factors set at specified levels. The article discusses the two types of DOEs: the full factorial design and the fractional factorial design. It explains the factors to be considered when selecting a procedure for propagating uncertainty. The article lists the categories of the popular types of uncertainty propagation methods, including simulation-based methods, local expansion methods, and numerical integration-based methods.

Cutting tool wear is a production management problem for manufacturing industries. It occurs along the cutting edge and on adjacent surfaces. This article describes steady-state wear mechanisms, tertiary wear mechanisms, and tool replacement. It provides information on tool failure and its consequences. The article details the modeling of tool wear by using the Taylor's tool life equation. The article concludes with information on the requirements of a successful tool life testing program: the test plan objective, designing the test, conducting the test, analyzing the results, and applying the results.

Machining of cast iron involves removing metal from the cast part, usually by cutting with a power-driven machine tool. This article discusses the factors that influence machinability, the methods used to evaluate machinability of cast irons, the effects of cast iron microstructure on cutting tool life, and the importance of as-cast surface integrity on the machining variation. It presents examples of cutting tool materials selection for different cast iron grades, and describes the effects of coolants on the machining of cast irons. A chart showing different cutting materials and cutting speed ranges for selected iron-carbon alloys is also presented. Different types of cutting tool wear observed during turning are schematically illustrated.

This article discusses the types of adaptive control (AC) systems for metal cutting according to the AC strategies used. These include adaptive control with optimization (ACO), adaptive control with constraints (ACC), and geometric adaptive control (GAC). The article details the milling and grinding systems based on the ACO strategy. It reviews the fundamentals of ACC systems followed by a description of a particular ACC system for a turning operation. The article also describes the basic characteristics of GAC systems and presents a particular GAC system for the turning of cylindrical parts. It examines the issues in the AC systems such as tool wear/breakage. Trends in the AC systems such as variable-gain ACC systems and integration of adaptive control into CAD/CAM/CIM systems are also discussed.

Statistics are extremely important tools in the operation of press shops, providing numerical process analysis capabilities. The most common use of statistics in the press shop is statistical process control (SPC) that uses statistical techniques such as control charts to analyze a process or its output to enable appropriate actions to be taken to achieve and maintain a state of statistical control. This article discusses the role of statistics in sheet metal forming operations, both in terms of SPC techniques, such as control charting, statistical deformation control, and experimental design, including single-variable studies, multivariable studies, and Taguchi experiments.

Braided structures are unique in their high level of conformability, torsional stability, and damage resistance. This article describes the classifications of braiding such as two-dimensional braiding and three-dimensional braiding. It presents the governing equations for computer-controlled braiding in a table. The article lists the applications of braided fabrics and composites. It discusses the formation, structure, and properties of two-dimensional braid composites and three-dimensional braid composites: the damage tolerance and the impact damage limitation.