In contrast to most plastic deformation processes, the shape of a machined component is not uniquely defined by the tooling. Instead, it is affected by complex interactions between tool geometry, material properties, and frictional stresses and is further complicated by tool wear. This chapter covers the mechanics and tribology of metal cutting processes. It discusses the factors that influence chip formation, including tool and process geometry, cutting forces and speeds, temperature, and stress distribution. It reviews the causes and effects of tool wear and explains how to predict and extend the life of cutting tools based on the material of construction, the use of cutting fluids, and the means of lubrication. It presents various methods for evaluating workpiece materials, chip formation, wear, and surface finish in cutting processes such as turning, milling, and drilling. It also discusses the mechanics and tribology of surface grinding and other forms of abrasive machining.

This chapter provides details on several specific binder formulations and a discussion of basic binder design concepts. The focus is on customization of the feedstock response to heating, pressurization, or solvent exposure for a specific shaping process. The discussion starts with the requirements of a binder system, the historical progression of binder formulations, and the use of binder alternatives to adapt to specific applications. The importance of binder handling strength to shape preservation is emphasized. The chapter provides information on the binders used for room-temperature shaping, namely slurry and tape casting systems.

The conversion of feedstock into a shape involves the application of heat and pressure, and possibly solvents. This chapter discusses the operating principle, advantages, limitations, and applications of such shaping processes, namely additive manufacturing, cold isostatic pressing, die compaction, extrusion, injection molding, slip casting, slurry processes, and tape casting. Information on equipment setup, requirements, and the various factors influencing these processes are described. In addition, the chapter provides information on novel approaches and processing costs applicable to these shaping processes.

Binder removal approaches involve various combinations of heat, solvents, vacuum, and pressure. In each variant, the goal is binder removal without component damage. This chapter addresses the factors that control success, showing how process decisions depend on the powder and binder characteristics. The chapter starts with a comparison of binder-, lubricant-, and polymer-removal situations that arise after powder shaping and then describes the general principles of binder removal in powder-binder techniques. The subsequent sections discuss in detail characteristics, operating procedure, equipment setup, advantages, limitations, and applications of first- and second-stage binder removal processes, as well as the factors influencing these processes. Cost issues associated with binder-removal technologies are also discussed.

This chapter provides details on powder-binder processing for three materials, namely precipitation-hardened 17-4 PH stainless steel, cemented carbides, and alumina. The types of powders, binders, feedstock, shaping processes, debinding, sintering cycles, compositions, microstructure, distortion, postsintering treatments, and mechanical properties are presented for each. The shaping options include powder-binder approaches such as binder jetting, injection molding, extrusion, slip and slurry casting, centrifugal casting, tape casting, and additive manufacturing. Sintering options are outlined with respect to attaining high final properties.