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orthogonal machining
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.t53740213
EISBN: 978-1-62708-308-9
... Abstract This chapter covers the practical aspects of machining, particularly for turning, milling, drilling, and grinding operations. It begins with a discussion on machinability and its impact on quality and cost. It then describes the dimensional and surface finish tolerances that can...
Abstract
This chapter covers the practical aspects of machining, particularly for turning, milling, drilling, and grinding operations. It begins with a discussion on machinability and its impact on quality and cost. It then describes the dimensional and surface finish tolerances that can be achieved through conventional machining methods, the mechanics of chip formation, the factors that affect tool wear, the selection and use of cutting fluids, and the determination of machining parameters based on force and power requirements. It also includes information on nontraditional machining processes such as electrical discharge, abrasive jet, and hydrodynamic machining, laser and electron beam machining, ultrasonic impact grinding, and electrical discharge wire cutting.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410151
EISBN: 978-1-62708-280-8
... Areas for gating for non-turbulent fill Tooling cost—depth of steel, offset planes, number of core pulls Ability for core support—core prints, setting, stability during mold tilting, core venting Number of cavities to be nested in a machine, with adequate shutoff or metal seal-off area Part...
Abstract
This chapter discusses the various factors pertinent to gravity permanent mold (GPM) castings, along with their advantages, limitations, and significance. The discussion covers the geometric factors, process and manufacturing elements, gating practices, and feeding principles of and pouring systems in GPM. The influences of mold coatings on GPM and low pressure permanent mold castings are described. The chapter also discusses various processes involved in the engineering of core boxes and cooling of GPM for casting integrity and cycle time control. It provides information on some of the processes involved in post-casting operations, namely de-coring and de-gating. The key design aspects for consideration in water quenching during the T6 heat treatment are reviewed. The chapter also provides information on two critical cycle events important in engineering at the manufacturing facility: tipper cycle planning and table or cell cycle planning.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1999
DOI: 10.31399/asm.tb.cmp.t66770001
EISBN: 978-1-62708-337-9
..., machine parts (for example, gears) would not be able to transmit as much load as would case-hardened parts. This is because case hardening produces significant compressive-residual stresses at the surface and within the hard case, whereas with through hardening, the residual stresses are much less...
Abstract
This chapter provides a brief but practical overview of the case carburizing process. It discusses the benefits and challenges of the process and compares and contrasts it with other hardening methods. It explains how design allowables and safety factors compensate for unknowns and familiarizes readers with the steps involved in determining case depth and verifying that case carbon requirements have been met.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.tt2.t51060251
EISBN: 978-1-62708-355-3
..., this time period is on the order of several to tens of microseconds. Uniaxial strain is defined mathematically as: (Eq 7) u x ≠ 0 , u y = u z = 0 where x is the direction of loading; u x is the displacement in that direction; and y and z are orthogonal directions...
Abstract
High strain rate tensile testing is used to understand the response of materials to dynamic loading. The behavior of materials under high strain rate tensile loads may differ considerably from that observed in conventional tensile tests. This chapter discusses the processes involved in determining strain rate effects in tension by conventional tensile tests and covers expanding ring tests, flat plate impact tests, split-Hopkinson pressure bar tests, and rotating wheel tests.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2012
DOI: 10.31399/asm.tb.smfpa.t53500301
EISBN: 978-1-62708-317-1
..., monitoring these variables and controlling their effects to produce high-quality products is critical and essential. The purpose of using sensor technologies is to improve the sheet metal forming process by increasing tool and machine uptimes, reducing setup and downtimes, and reducing scrap. For example...
Abstract
This chapter discusses the types of sensors used in sheet forming operations and the information they provide. It explains how force sensors protect equipment from overloads due to tool wear, friction, and misfeeds, how displacement and proximity sensors help to prevent die crashes, how acoustic emission, ultrasonic, and eddy current sensors detect tool breakage and part defects such as cracks, and how roller ball and optical sensors measure material flow. It also discusses the role of draw-in, wrinkle, oil-monitoring, and vision sensors and explains how material properties can be derived in real time from various sensor outputs.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2022
DOI: 10.31399/asm.tb.isceg.t59320063
EISBN: 978-1-62708-332-4
... orthogonal planes. The axes are established in relation to the position of the six locators. Locators are not positioned on cored surfaces to avoid inconsistencies due to core setting variances and the dimensional variability of cores. The part geometry is approved with the coordinate measuring machine...
Abstract
The casting engineer contributes to a successful component design by offering expertise in molding, core making, and material characteristics and by recommending the most suitable casting process to use to meet quality and cost targets. The casting engineer's responsibilities include recommending locator positioning; advising about lugs, hooks, or holes for casting handling through all processes; determining the choice of a parting plane and pouring orientation; designing cores for accurate positioning, suitable venting, and proper cleaning; guiding decisions about wall thicknesses and junctions; making suggestions about casting design to eliminate distortion; optimizing the gating design for slag-free metal; and establishing the feeding techniques to eliminate shrink porosity. This chapter provides the guidelines for these responsibilities. In addition, the guidelines for the use of chaplets and chills in cast iron castings; guidelines for drafts, machine stock, tolerances, and contraction or shrink rule; and guidelines for pattern layouts and nesting are also covered.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870119
EISBN: 978-1-62708-314-0
... improve the quality and productivity by building their own impregnation machines. One simple example is shown in Fig. 5.2 , in which a dry reinforcement is being impregnated through rollers with a liquid resin. Fig. 5.1 Typical wet lay-up operation Fig. 5.2 Example of a simple...
Abstract
This chapter familiarizes readers with the many and varied thermoset composite fabrication processes and the types of applications for which they were developed. It describes wet lay-up, prepreg lay-up, and low-temperature vacuum bag curing prepreg processes, which are best suited for low-volume, medium-sized and larger parts. It also discusses filament winding and preforming processes (including weaving, knitting, stitching, and braiding) in addition to resin-transfer molding, resin film infusion, and pultrusion.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2018
DOI: 10.31399/asm.tb.msisep.t59220353
EISBN: 978-1-62708-259-4
... in a material and how they are altered in forming processes or during subsequent machining operation. The effect of deformation is much clearer in a longitudinal section (containing the direction of main deformation) than in the transverse section, as can be observed in Fig. 11.4 and 11.5 . From...
Abstract
This chapter discusses the effects of hot working on the structure and properties of steel. It explains how working steels at high temperatures promotes diffusion, which helps close cavities and pores, and how it changes the shape and distribution of segregates, offsetting their effect. It describes the effect of hot working on nonmetallic inclusions and the many properties influenced by them. It discusses the recrystallization mechanism by which hot working produces microstructural changes and explains how to control it by adjusting temperature, degree of reduction, and cooling rates. It describes special cases of segregation, including banding and why it occurs, and the application of closed die forging. The chapter also presents several examples of hot working defects, including forging laps, cracks, and overheated or burned steel.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2012
DOI: 10.31399/asm.tb.smfpa.t53500227
EISBN: 978-1-62708-317-1
... mechanism, high-velocity mechanical forming machines can be subdivided into: Pneumatically-driven machines Explosively-driven machines Electromagnetically-driven machines Among these, currently only electromagnetically-driven machines, such as the blanking press shown in Fig. 11.9...
Abstract
Any forming process that converts stored energy to plastic deformation in less than a few milliseconds is considered a high-velocity or impulse forming process. This chapter discusses the operating principles, equipment, and applications of the most common high-rate forming processes, including high-velocity hydroforming, high-velocity mechanical forming, and electromagnetic or energy-based forming.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 July 2009
DOI: 10.31399/asm.tb.bcp.t52230295
EISBN: 978-1-62708-298-3
... Abstract The vast majority of beryllium products are manufactured from blocks, forms, or billets of compacted powder that are machined or worked into shape. This chapter describes the metalworking processes used, including rolling, forming, forging, extrusion, drawing, and spinning. It covers...
Abstract
The vast majority of beryllium products are manufactured from blocks, forms, or billets of compacted powder that are machined or worked into shape. This chapter describes the metalworking processes used, including rolling, forming, forging, extrusion, drawing, and spinning. It covers the qualitative and quantitative aspects of each process and provides examples showing how they are implemented and the results that can be achieved. The chapter also discusses the issue of beryllium’s low formability and describes some of the advancements that have been made in near-net shape processing.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2015
DOI: 10.31399/asm.tb.spsp2.t54410163
EISBN: 978-1-62708-265-5
... machine ( Ref 9.8 ). Machines that cast other shapes have similar components. A key feature of modern steelmaking is the use of basic oxygen steelmaking (BOS) furnaces or electric arc furnaces (EAF) to perform the functions of melting (in the case of EAF steelmaking) and primary refinement of liquid steel...
Abstract
Inclusions and chemical segregation are factors in many process-induced failures involving steel parts. Inclusions are nonmetallic compounds introduced during production; segregation is a type of chemical partitioning that occurs during solidification. This chapter discusses the origins of segregation and inclusions and their effect on the mechanical properties and microstructure of steel. It explains how to identify various types of inclusions and characteristic segregation patterns, such as banding. It also describes the effect of hot work processing on solidification structure and the chemical variations produced by interdendritic segregation.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2019
DOI: 10.31399/asm.tb.mfadr7.t91110335
EISBN: 978-1-62708-247-1
... profiling have historically not been performed via ToF-SIMS because the pulsing of the primary beam results in very low duty cycles. More recently, orthogonal ToF (o-ToF) spectrometers have been integrated with LMIS FIBs with some success [31] . O-ToF spectrometers pulse the secondary ion beam while making...
Abstract
With the commercialization of heavier and lighter ion beams, adoption of focused ion beam (FIB) use for analysis of challenging regions of interest (ROI) has grown. In this chapter, the authors focus on highlighting commercially available and complementary FIB technologies and their implementation challenges and application trends.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870031
EISBN: 978-1-62708-314-0
... shapes and is very difficult to machine. Other high-temperature ceramic fibers, such as silicon carbide (Nicalon), aluminum oxide, and alumina boria silica (Nextel), are frequently used in ceramic-based composites but rarely in polymer-based composites. The stress-strain curves in Fig. 2.2 show...
Abstract
This chapter discusses the properties and processing characteristics of glass, aramid, carbon, and ultra-high molecular weight polyethylene fibers and related product forms, including woven fabrics, prepreg, and reinforced mats. It also includes a review of fiber terminology as well as physical and mechanical property data for commercially important high-strength fibers.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2012
DOI: 10.31399/asm.tb.lmub.t53550569
EISBN: 978-1-62708-307-2
... irons (50 to 65 HRC). Their primary application area, however, is for roughing, finishing, and milling of difficult-to-machine age-hardened nickel-base superalloys. As shown in Fig. 11.8 , much higher cutting speeds and longer tool life can be achieved when machining these materials with whisker...
Abstract
Ceramic-matrix composites possess many of the desirable qualities of monolithic ceramics, but are much tougher because of the reinforcements. This chapter explains how reinforcements are used in ceramic-matrix composites and how they alter energy-dissipating mechanisms and load-carrying behaviors. It compares the stress-strain curves for monolithic ceramics and ceramic-matrix composites, noting improvements afforded by the addition of reinforcements. It then goes on to discuss the key attributes, properties, and applications of discontinuously reinforced ceramic composites, continuous fiber ceramic composites, and carbon-carbon composites. It also describes a number of ceramic-matrix composite processing methods, including cold pressing and sintering, hot pressing, reaction bonding, directed metal oxidation, and liquid, vapor, and polymer infiltration.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1999
DOI: 10.31399/asm.tb.cmp.t66770135
EISBN: 978-1-62708-337-9
... toughness When a case-hardened machine part is subjected to normal loading, its failure, should failure occur, usually results from contact damage or damage due to bending stresses, possibly acting on an engineering or metallurgical stress raiser. Contact damage often initiates at the surface...
Abstract
The design of case-hardened components is an iterative process, requiring the consideration of multiple interrelated factors. This chapter walks readers through the steps involved in selecting an appropriate material and assessing the influence of alloy composition and cooling rate on core properties including hardenability, microstructure, tensile and yield strength, ductility, toughness, and fatigue resistance. It likewise explains how carbon affects case hardenability, surface hardness, and case toughness and how case depth influences residual stresses and bending and contact fatigue. It also discusses the effect of quenching methods and addresses the issue of distortion.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2022
DOI: 10.31399/asm.tb.isceg.t59320217
EISBN: 978-1-62708-332-4
..., machining process engineers, and quality control engineers. They interact to arrive at the optimum solutions for part orientation during pouring and the selection of the parting plane, trying to meet individual needs as much as possible 12.5.3.1.1 General Guideline Illustrations Thin-walled...
Abstract
Steel is broadly classified as plain-carbon steels, low-alloy steels, and high-alloy steels. This chapter begins by describing microconstituents of low- and medium-carbon steel, including bainite and martensite. This is followed by a section discussing the effect of alloying elements on steel. Then, it provides an overview of steel casting applications. Next, the chapter reviews engineering guidelines for steel castings and feeder design. The following section provides information on feeding aids. Further, the chapter describes the elements of gating systems for steel castings. It also describes the alloys, properties, applications, and engineering details of steel. Finally, the chapter explains defects in steel castings and presents guidelines for problem solving with examples.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 July 2009
DOI: 10.31399/asm.tb.bcp.t52230267
EISBN: 978-1-62708-298-3
... metallurgical techniques for beryllium were first developed in 1946. Currently, powder metallurgy is the main processing route to produce beryllium components. The vacuum hot pressing method results in a fine-grained, machinable form of the material. The random orientation and fine grain size of the powder...
Abstract
Powder metallurgy plays a central role in the production of nearly all beryllium components. This chapter describes the primary steps in the powder metal process and the work that has been done to improve each one. It explains how beryllium powders are made and how they are consolidated prior to sintering. It also compares and contrasts the properties of beryllium products made using different methods and provides composition and particle size data on commercially available powders.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2019
DOI: 10.31399/asm.tb.mfadr7.t91110550
EISBN: 978-1-62708-247-1
... razor blade cutting process. Higher viscosity and thicker thermal interface materials (TIM) increase the likelihood of damaging the die. In many cases, a CNC high speed milling machine is the preferred method to remove the lid. The perimeter of the lid is milled away, and then a solvent or heating...
Abstract
The complexity of semiconductor chips and their packages has continuously challenged the known methods to analyze them. With larger laminates and the inclusion of multiple stacked die, methods to analyze modern semiconductor products are being pushed toward their limits to support these 2.5D and 3D packages. This article focuses on these methods of fault isolation, non-destructive imaging, and destructive techniques through an iterative process for failure analysis of complex packages.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 March 2006
DOI: 10.31399/asm.tb.fdsm.t69870375
EISBN: 978-1-62708-344-7
... correlations for carbon and alloy steels. Source: Ref A.53 Fig. A.47 Bending arrangements. (a) Three-point loadings. (b) Four-point loadings Fig. A.50 Schematic of modern fatigue testing machine. Source: Ref A.55 Fig. A.51 Typical hydraulically operated self-aligning grip...
Abstract
This appendix provides supplemental information on the metallurgical aspects of atomic structure, the use of dislocation theory, heat treatment processes and procedures, important engineering materials and strengthening mechanisms, and the nature of elastic, plastic, and creep strain components. It also provides information on mechanical property and fatigue testing, the use of hysteresis energy to analyze fatigue, a procedure for inverting equations to solve for dependent variables, and a method for dealing with the statistical nature of failure.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1984
DOI: 10.31399/asm.tb.mpp.t67850001
EISBN: 978-1-62708-260-0
Abstract
This chapter describes several macroscopic examination techniques, including macroetching, contact printing, fracturing, and lead exudation. It explains how each method is implemented, why it is used, and what it reveals about manufacturing processes, defects, imperfections, and failure mechanisms.
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