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shear cutting
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Image
Published: 01 September 2005
Fig. 4 Progressive action in shear cutting teeth of an external spur gear. Shear cutting operation proceeds from roughing (a) to intermediate (b) to finishing (c) operations.
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2005
DOI: 10.31399/asm.tb.gmpm.t51250089
EISBN: 978-1-62708-345-4
... Progressive action of broach teeth in cutting teeth of an internal spur gear Fig. 4 Progressive action in shear cutting teeth of an external spur gear. Shear cutting operation proceeds from roughing (a) to intermediate (b) to finishing (c) operations. Fig. 5 Schematic of hobbing action...
Abstract
Metal removal processes for gear manufacture can be grouped into two general categories: rough machining (or gear cutting) and finishing (or high-precision machining). This chapter discusses the processes involved in machining for bevel and other gears. The chapter describes the type of gear as the major variable and discusses the machining methods best suited to specific conditions. Next, the chapter provides information on gear cutter material and nominal speeds and feeds for gear hobbing. Further, it describes the cutting fluids recommended for gear cutting and presents a comparison of steels for gear cutting. The operating principles of computer numerical control and hobbing machines are also covered. This is followed by sections that discuss the processes involved in grinding, honing, and lapping of gears. Finally, the chapter provides information on the superfinishing of gears.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040151
EISBN: 978-1-62708-300-3
... Abstract Separation of billets by shearing avoids material loss and is considerably faster than sawing or cutting. This chapter discusses the billet shearing process, the characteristics of sheared surfaces, and the effect of various operating parameters on surface quality. It also includes...
Abstract
Separation of billets by shearing avoids material loss and is considerably faster than sawing or cutting. This chapter discusses the billet shearing process, the characteristics of sheared surfaces, and the effect of various operating parameters on surface quality. It also includes formulas for calculating shearing force, work, and power and describes various ways to increase production rates.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2012
DOI: 10.31399/asm.tb.smfpa.t53500001
EISBN: 978-1-62708-317-1
... is the total length (perimeter) of the cut, t is the sheet material thickness, S s is the shear strength of the material, and A p is the cross-sectional area of the punch. Stripping force is the force needed to free the blank from the die or the strip from the punch when they stick or jam because...
Abstract
This chapter provides an overview of the blanking process and the forces and stresses involved. It discusses the factors that affect part quality and tool life, including punch and die geometry, stagger, clearance, and wear as well as punch velocities, misalignment, and snap-thru forces. It also discusses ultra-high-speed blanking, fine blanking, and shearing, and the use finite-element simulations to predict part edge quality.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.t53740163
EISBN: 978-1-62708-308-9
... at room temperature and must therefore be formed at elevated temperatures. Preparation of Plate and Flat Sheet Prior to forming, the plate or sheet must be cut to the proper size. This can be done by a number of methods—the most prevalent being sawing, shearing, and oxyfuel gas cutting. Because...
Abstract
This chapter describes sheet metal forming operations, including cutting, blanking, piercing, and bending as well as deep drawing, spinning, press-brake and stretch forming, fluid forming, and drop hammer and electromagnetic forming. It also discusses the selection and use of die materials and lubricants along with superplastic forming techniques.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270084
EISBN: 978-1-62708-301-0
.... The hub of the wheel had sheared off. Parallel to the fracture surface, there was circumferential cracking near the fillet of the flange. The crack had proceeded from the outer surface at the fillet to the inner. Fractography revealed cleavage mode. The rim had failed due to excessive pressure of air...
Abstract
An aircraft tire burst while inflating, causing one of the flanges on the wheel hub to fracture. This chapter provides a summary of the investigation along with key findings. It includes images of the damaged hub and describes how various parts failed as the pressure in the tire increased. It explains that the hub material was of good quality under uniform load and that it fractured quickly by cleavage due to the force exerted by the overinflated tire.
Image
Published: 01 December 1984
Figure 3-2 Sample preparation can alter the microstructure, as demonstrated by these two micrographs of dual-phase sheet steel. Shearing (left) transformed the retained austenite to martensite, while abrasive cutting (right) did not (retained austenite are small, outlined white particles
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2005
DOI: 10.31399/asm.tb.gmpm.t51250001
EISBN: 978-1-62708-345-4
...Gear cutting table showing various tooth dimensions for different diametral pitches of spur gears Table 1 Gear cutting table showing various tooth dimensions for different diametral pitches of spur gears Diametral pitch Circular pitch, in. Thickness of tooth on pitch line, in. Depth...
Abstract
This chapter begins with a review of some of the terms used in the gear industry to describe the design of gears and gear geometries. It then discusses the types of gears that operate on parallel shafts, intersecting shafts, and nonparallel and nonintersecting shafts. Next, the processes involved in the selection of gear are discussed, followed by information on the basic stresses applied to a gear tooth, the strength of a gear tooth, and the most widely used gear materials. Further, the chapter briefly reviews gear manufacturing methods and the heat treating processing steps including prehardening processes, through hardening, and case hardening processes.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270053
EISBN: 978-1-62708-301-0
... exhibited two distinct fracture features. Many of the strands had uniformly necked down as in a classical tensile failure, but others showed evidence of cut by a shearing tool. A criminal act was suspected. Further investigations revealed that a disgruntled worker had sabotaged the operation by hacking...
Abstract
This chapter discusses the role of failure analysis in cases involving product liability, property damage, and personal injury litigation. It also explains how material science and technology shed light on criminal activities such as smuggling, counterfeiting, theft, and the willful destruction of property.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 30 November 2013
DOI: 10.31399/asm.tb.uhcf3.t53630023
EISBN: 978-1-62708-270-9
..., with little or no bending distortion involved. In single-shear fractures, two closely fitting parallel surfaces with sharp edges, as shown in Fig. 7(a) , can shear, or cut, a third material between them if they move toward each other. Shear or sliding fracture occurs on the dashed line at the interface...
Abstract
The relationship of stress and strength gradients must be considered simultaneously in analysis of a particular type of fracture. This chapter discusses the principal elastic stress distribution in members of various shapes under different types of pure loads. A basic understanding of both the stress and strength gradients of metal parts with and without stress concentrations and under different types of loading is provided. The chapter also describes the effect of service conditions on applied stresses.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2012
DOI: 10.31399/asm.tb.smff.t53400233
EISBN: 978-1-62708-316-4
... Dies used in presses for bending sheet metal or wire parts into various shapes. Appendix B: Glossary / 235 blanking The operation of punching, cutting, or shearing a piece out of stock to a predeter- mined shape. bologna See kidney. bolster plate A plate to which dies can be fas- tened the assembly...
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2012
DOI: 10.31399/asm.tb.smff.9781627083164
EISBN: 978-1-62708-316-4
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 March 2002
DOI: 10.31399/asm.tb.mgppis.t60400169
EISBN: 978-1-62708-258-7
... used without a coolant and thus create damage to the cut surface of the specimen. However, once a saw-cut specimen is obtained in the field, it is further cut to a smaller size using proper metallographic procedures in the laboratory. Shear A small shear is a very common way to prepare...
Abstract
This chapter instructs the metallographer on the basic skills required to prepare a polished metallographic specimen. It is organized in a chronological sequence starting with the information-gathering process on the material being investigated, then moving on to sectioning, mounting, grinding, and polishing processes, and ending with methods used to properly store metallographic specimens. The discussion covers the preparation procedures, the materials being investigated, and equipment used to perform these procedures.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270120
EISBN: 978-1-62708-301-0
... of the The fracture surface of the port side strut was of the slant type strut. with features typical of shear overload (Fig. CH23.5). There were no regions of delayed failure. A portion of the strut containing the region A was cut, ultra- sonically cleaned, and examined in a SEM. Striations typical of Discussion...
Abstract
This chapter describes an investigation following an aircraft accident in which the main undercarriage struts had failed. Visual examination revealed that the starboard strut fractured about 13 cm from the end nearest the underside of the wing. A close-up view of the fracture surface indicated that cracking initiated at the outer periphery of the strut and propagated inward until overload fracture occurred. SEM imaging revealed fatigue striations along the outer periphery and dimples elsewhere, indicative of tensile overload. Based on these observations, investigators concluded that the starboard strut failed by fatigue, which overloaded the port side strut as evidenced by its slant type fracture pattern.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270141
EISBN: 978-1-62708-301-0
... before ending in a shear lip on the convex side. Fig. CH32.1 Fracture surface of the blade showing chevron marks Testing Procedure and Results Scanning Electron Fractography A small section of the blade was cut in one of these regions and the fracture surface was observed in the SEM...
Abstract
A compressor blade made of titanium alloy fractured during an engine test. The material and processing conditions of the blade were found to be satisfactory, turning the focus of the investigation to operating anomalies and human error. A photograph of the failed blade shows well-defined chevron marks along the fracture surface that end in a shear lip on the convex side. Further examination using a SEM shows that the failure was due to overload. Based on these observations and the results of tensile testing and microstructural analysis, investigators concluded that a sudden impact load on the concave side of the blade caused it to fracture.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2012
DOI: 10.31399/asm.tb.ffub.t53610461
EISBN: 978-1-62708-303-4
... can be characterized by a single key word: cutting . Abrasive wear occurs when hard particles suspended in a fluid or projections from one surface roll or slide under pressure against another surface, as shown in Fig. 1 , thereby cutting the other surface. Indeed, machining would fall...
Abstract
This chapter discusses the causes and effects of wear along with prevention methods. It covers abrasive, erosive, erosion-corrosion, grinding, gouging, adhesive, and fretting wear. It also discusses various forms of contact-stress fatigue, including subsurface-origin fatigue, surface-origin fatigue, subcase-origin fatigue (spalling fatigue), and cavitation fatigue.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270154
EISBN: 978-1-62708-301-0
... Fractography A small piece of the sheet metal from this region was cut and examined in the SEM. Fatigue striations were clearly seen ( Fig. CH38.1 ). The fracture on the outer skin region away from the rivet hole up to the leading edge showed reverse slant fracture edge and on the fracture surface...
Abstract
The aluminum alloy skin on the main rotor blade of a helicopter tore off in flight, and an investigation was subsequently conducted to find the cause. Visual examination and SEM fractography revealed that a fatigue crack originated on the underside of a rivet hole at the trailing edge of the blade. The crack then propagated through the outer skin toward the leading edge of the blade. Once the fatigue crack reached critical length, the sheet metal fractured catastrophically, tearing away from the blade.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 March 2002
DOI: 10.31399/asm.tb.stg2.t61280189
EISBN: 978-1-62708-267-9
... high dynamic shear strength Contain, in their microstructure, hard carbides that make superalloys abrasive Work harden during metal cutting Possess poor thermal diffusivity, which leads to high cutting tool lip temperatures Form a tough, continuous chip during metal cutting...
Abstract
The qualities that make superalloys excellent engineering materials also make them difficult to machine. This chapter discusses the challenges involved in machining superalloys and the factors that determine machinability. It addresses material removal rates, cutting tool materials, tool life, and practical issues such as set up time, tool changes, and production scheduling. It describes several machining processes, including turning, boring, planing, trepanning, shaping, broaching, drilling, tapping, thread milling, and grinding. It also provides information on toolholders, fixturing, cutting and grinding fluids, and tooling modifications.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270115
EISBN: 978-1-62708-301-0
... Abstract Two compressor rotors of similar design and construction were severely damaged during operation. In one rotor, all the blades in the third and fourth stages had been sheared off and some had lifted from the dovetail portion of the drum. The damage in the other rotor was more extensive...
Abstract
Two compressor rotors of similar design and construction were severely damaged during operation. In one rotor, all the blades in the third and fourth stages had been sheared off and some had lifted from the dovetail portion of the drum. The damage in the other rotor was more extensive. Most of the blades in the first four stages had sheared off and many lifted from the dovetail region, particularly in the first two stages where several mounting dovetails had also fractured. Based on visual examination and the results of SEM fractography, metallography, and chemical analysis, investigators concluded that the compressor rotors failed due to stress-corrosion cracking in the dovetail mountings. They also provided recommendations to prevent or mitigate future occurrences.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2021
DOI: 10.31399/asm.tb.ciktmse.t56020001
EISBN: 978-1-62708-389-8
...–solution strengthening. One way to think about a screw dislocation is to start with a deck of cards. A “cut” is first made partway into the cards. Then, the cards are sheared in the plane of the cut as shown by the magenta arrows in Fig. 5 . The result is a screw dislocation as represented...
Abstract
Alloying, heat treating, and work hardening are widely used to control material properties, and though they take different approaches, they all focus on imperfections of one type or other. This chapter provides readers with essential background on these material imperfections and their relevance in design and manufacturing. It begins with a review of compositional impurities, the physical arrangement of atoms in solid solution, and the factors that determine maximum solubility. It then describes different types of structural imperfections, including point, line, and planar defects, and how they respond to applied stresses and strains. The chapter makes extensive use of graphics to illustrate crystal lattice structures and related concepts such as vacancies and interstitial sites, ion migration, volume expansion, antisite defects, edge and screw dislocations, slip planes, twinning planes, and dislocation passage through precipitates. It also points out important structure-property correlations.