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workpiece failures

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Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006826
EISBN: 978-1-62708-329-4
... Abstract The first part of this article focuses on two major forms of machining-related failures, namely machining workpiece (in-process) failures and machined part (in-service) failures. Discussion centers on machining conditions and metallurgical factors contributing to (in-process) workpiece...
Image
Published: 30 August 2021
Fig. 3 Illustration of various aspects of the surface integrity and surface texture principles that may increase the risk of workpiece failures. Source: Ref 8 More
Image
Published: 01 August 2013
on a strip chart. Workpiece failure is indicated by a torque rise of 1.1 N · m (10 lbf · in.) above the steady-state value or breakage of the shear pin, whichever failure criteria is reached first (per ASTMD 2625-83). Courtesy of Falex Corporation More
Series: ASM Handbook
Volume: 18
Publisher: ASM International
Published: 31 December 2017
DOI: 10.31399/asm.hb.v18.a0006423
EISBN: 978-1-62708-192-4
... to the workpiece-die interface. The article describes the most common types and causes of die wear: abrasive wear, adhesive wear, surface fatigue wear, thermal fatigue wear, and catastrophic failure. It concludes with a discussion on the surface treatment and texturing that are used to reduce die wear in drawing...
Book: Machining
Series: ASM Handbook
Volume: 16
Publisher: ASM International
Published: 01 January 1989
DOI: 10.31399/asm.hb.v16.a0002116
EISBN: 978-1-62708-188-7
... Abstract This article provides an overview of the independent and dependent variables of a machining process. Independent variables include workpiece material, specific machining processes, and tool materials and geometry. Cutting force and power, surface finish, and tool wear and failure...
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005121
EISBN: 978-1-62708-186-3
... selection for drawing. It explains the types of dies used for drawing sheet metal and the effects of process variables and material variables on deep drawing. The process variables that affect the success or failure of a deep-drawing operation include the punch and die radii, punch-to-die clearance, press...
Series: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005842
EISBN: 978-1-62708-167-2
... Degradation of the flux concentrator due to its overheating is the most typical failure mode ( Fig. 24 ). There are three causes of concentrator overheating: Heat flow from the surface of the heated workpiece (due to thermal radiation and heat convection, Ref 5 , 17 ). In the majority of induction...
Image
Published: 01 January 2024
Fig. 40 Localized surface tinting near the fractured tip of a drill bit implicated abusive service as the cause of failure. Failure occurred by ductile torsional overload (oriented perpendicular to the bit axis) as the bit overheated on the workpiece. More
Book: Machining
Series: ASM Handbook
Volume: 16
Publisher: ASM International
Published: 01 January 1989
DOI: 10.31399/asm.hb.v16.a0002177
EISBN: 978-1-62708-188-7
...). Machine tests are designed to measure the resistance of cutting tools to these failure mechanisms. This is accomplished by matching the workpiece and tool materials, adjusting machining parameters over the likely application range, and then carefully evaluating the failure modes and their relationship...
Book: Machining
Series: ASM Handbook
Volume: 16
Publisher: ASM International
Published: 01 January 1989
DOI: 10.31399/asm.hb.v16.a0002120
EISBN: 978-1-62708-188-7
... Abstract 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...
Book Chapter

Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0003987
EISBN: 978-1-62708-185-6
... failure of the die does not take place. Hammers and Presses In coining, the workpiece is squeezed between the dies so that the entire surface area is simultaneously loaded above the yield strength. To achieve the desired deformation of metal, the load determined from the compressive yield strength...
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005594
EISBN: 978-1-62708-174-0
... (RSW) is a process in which faying surfaces are joined in one or more spots by the heat generated by resistance to the flow of electric current through workpieces that are held together under force by electrodes. The contacting surfaces in the region of current concentration are heated by a short-time...
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006500
EISBN: 978-1-62708-207-5
... and the substrate. The workpiece can then be ground or machined to produce useful products. This process is typically used to take advantage of different properties between the substrate and deposited layer, perhaps achieving a useful combination of surface hardness and substrate toughness, for example. Fig. 1...
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005127
EISBN: 978-1-62708-186-3
... and electromagnetic forming. These techniques are distinct from most other metal forming methods in that the explosive or electromagnetic force first accelerates the workpiece to a high velocity, and the kinetic energy of the workpiece is significant. The sheet metal workpiece then changes shape, either as it strikes...
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005633
EISBN: 978-1-62708-174-0
... 9.00 121 4.75 140 5.50 76.2 3.00 241 9.50 127 5.00 (a) Diameter of rounds or tubing, or minimum dimension of other sections. (b) Backup is recommended for all workpiece diameters or minimum dimensions over 38.1 mm (1.50 in.). Failure Origins in Flash Welds Porosity...
Book Chapter

Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0004012
EISBN: 978-1-62708-185-6
... impart smooth, burnished roots and flanks to threads. Rolled threads are free of tears, chatter marks, or cutting-tool marks common to cut threads. Such imperfections nucleate wear and can serve as starting points for fatigue failure. Surface roughness on rolled threads is usually from 0.20 to 0.60 μm (8...
Series: ASM Handbook
Volume: 8
Publisher: ASM International
Published: 01 January 2000
DOI: 10.31399/asm.hb.v08.a0003258
EISBN: 978-1-62708-176-4
... types of failure in metalworking processes: Local or total separation of the metal: Surface cracking in upsetting or open-die forging, internal cracking in extrusion or drawing, and necking and subsequent tearing of sheet metals during forming Buckling: Upsetting of slender workpieces...
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005595
EISBN: 978-1-62708-174-0
... pressure to obtain a weld between the metals. In this process, the sudden discharge of a capacitor bank through a coil of relatively few turns produces a strong transient magnetic field. If this field is coupled with a metal workpiece, an intense impulsive force acts on the material and accelerates...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003507
EISBN: 978-1-62708-180-1
... Abstract This article describes the general root causes of failure associated with wrought metals and metalworking. This includes a brief review of the discontinuities or imperfections that may be the common sources of failure-inducing defects in bulk working of wrought products. The article...
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005158
EISBN: 978-1-62708-186-3
... electrode and workpiece. The sparks travel through a dielectric fluid (typically a light oil) at a controlled distance. Both electrode and work must be electrically conductive. The EDM process has several advantages when machining difficult geometries or materials with poor machinability. Cavities with thin...