Table Of Content

Materials Forming, Machining and Tribology J. Paulo Davim Editor Modern Manufacturing Engineering Materials Forming, Machining and Tribology Series editor J. Paulo Davim, Aveiro, Portugal More information about this series at http://www.springer.com/series/11181 J. Paulo Davim Editor Modern Manufacturing Engineering 123 Editor J.PauloDavim Department ofMechanical Engineering University of Aveiro Aveiro Portugal ISSN 2195-0911 ISSN 2195-092X (electronic) Materials Forming,Machining andTribology ISBN978-3-319-20151-1 ISBN978-3-319-20152-8 (eBook) DOI 10.1007/978-3-319-20152-8 LibraryofCongressControlNumber:2015941349 SpringerChamHeidelbergNewYorkDordrechtLondon ©SpringerInternationalPublishingSwitzerland2015 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission orinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodologynowknownorhereafterdeveloped. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfrom therelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authorsortheeditorsgiveawarranty,expressorimplied,withrespecttothematerialcontainedhereinor foranyerrorsoromissionsthatmayhavebeenmade. Printedonacid-freepaper SpringerInternationalPublishingAGSwitzerlandispartofSpringerScience+BusinessMedia (www.springer.com) Preface Nowadays, Manufacturing Engineering is defined as a discipline “which involves theabilitytoplantheprocessesandpracticesofmanufacturingandtoresearchand develop systems, processes, machines, tools and equipment for producing quality products”. Manufacturing is the “art” of transformation of materials into products. Fundamental subjects of manufacturing engineering include: materials technology, formingandsheetmetalworking,traditionalandnon-traditionalmachining,joining and assembly processes, automation and manufacturing systems, green and lean manufacturing, etc. The purpose of this book is to present a collection of examples illustrating research in “Modern Manufacturing Engineering”. Chapter 1 of the book provides submicro- and nanostructuring of materials by severe plastic deformation. Chapter 2isdedicatedtocrossrolling(ametalformingprocess).Chapter3describesafinite element method in machining processes. Chapter 4 contains information about machining and machining modelling of metal matrix composites. Chapter 5 contains information about intelligent CNC tool path optimization for sculptured surface machining through virus-evolutionary genetic algorithm. Chapter 6 is dedicated to friction stir welding: (scope and recent developments). Chapter 7 describes innovative joining technologies based on tube. Chapter 8 contains information about lean manufacturing. Chapter 9 provides object-based final-year project (designing and manufacturing a quick stop device). Finally, Chap. 10 is dedicated to quantifying quality of learning during teaching an undergraduate unit (manufacturing processes). This book can be used as a research book for final undergraduate engineering course or as a topic on manufacturing engineering at the postgraduate level. Also, this book can serve as a useful reference for academics, researchers, mechanical, manufacturing, industrial and materials engineers, professionals in manufacturing and related industries. The scientific interest in this book is evident for many important centres of research, laboratories and universities as well as industry. Therefore, it is hoped this book will inspire and enthuse others to undertake research in manufacturing engineering. v vi Preface TheEditoracknowledgesSpringerforthisopportunityandfortheirenthusiastic and professional support. Finally, I would like to thank all the chapter authors for their availability for this work. Aveiro, Portugal J. Paulo Davim May 2015 Contents 1 Submicro and Nanostructuring of Materials by Severe Plastic Deformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Viktor P. Astakhov 2 Cross Rolling: A Metal Forming Process. . . . . . . . . . . . . . . . . . 41 Matruprasad Rout, Surjya K. Pal and Shiv B. Singh 3 Finite Element Method in Machining Processes: A Review. . . . . 65 Carlos H. Lauro, Lincoln C. Brandão, Sergio L.M. Ribeiro Filho, Robertt A.F. Valente and J. Paulo Davim 4 Machining and Machining Modeling of Metal Matrix Composites—A Review. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Angelos P. Markopoulos, Ioannis S. Pressas, Ioannis G. Papantoniou, Nikolaos E. Karkalos and J. Paulo Davim 5 Intelligent CNC Tool Path Optimization for Sculptured Surface Machining Through a Virus-Evolutionary Genetic Algorithm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Nikolaos A. Fountas, Nikolaos M. Vaxevanidis, Constantinos I. Stergiou and Redha Benhadj-Djilali 6 Friction Stir Welding: Scope and Recent Development. . . . . . . . 179 Rahul Jain, Kanchan Kumari, Ram Kumar Kesharwani, Sachin Kumar, Surjya K. Pal, Shiv B. Singh, Sushanta K. Panda and Arun K. Samantaray 7 Innovative Joining Technologies Based on Tube Forming. . . . . . 231 L.M. Alves, C.M.A. Silva and P.A.F. Martins vii viii Contents 8 Lean Manufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 Ali Hosseini, Hossam A. Kishawy and Hussein M. Hussein 9 Object-Based Final-Year Project: Designing and Manufacturing a Quick Stop Device . . . . . . . . . . . . . . . . . . 271 A. Pramanik, Hem Sanghvi and A.K. Basak 10 Quantifying Quality of Learning During Teaching an Undergraduate Unit: Manufacturing Processes . . . . . . . . . . . 301 A. Pramanik and M.N. Islam Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 Chapter 1 Submicro and Nanostructuring of Materials by Severe Plastic Deformation Viktor P. Astakhov Abstract This chapter discusses the development of the metallurgical structure of submicro and nanostructured metallic materials in Severe Plastic Deformation (SPD). Particular attention is paid to Equal-Channel Angular Pressing (ECAP) as the most feasible way to achieve the major objectives of grain refinement, distin- guished as strength enhancement, superplasticity, and improvement in creep resistance. The need and essence of the multi-pass process is explained in detail. Particular attention is paid to the deformation mode in SPD. It is shown that the discussed objectives can be achieved if this deformation mode is simple shear. The chapter also presents the development and modeling of large strain extrusion machining (LSEM), comparing the results obtained in this process with those in ECAP. 1.1 Introduction Thereisconsiderablecurrentinterestinfabricatingmetalswithultrafinegrainsizes. Several methods are now available for attaining metals with extremely small grain sizes, usually within the nanometer range, including inert gas condensation, high energy ball milling, and sliding wear. However, these procedures have not been developed sufficiently to date though they are capable of producing large bulk samples which are free of any residual porosity. As a result of these limitations, attention has been devoted to the alternative processes of Equal-Channel Angular Pressing (ECAP) and High-Pressure Torsion (HPT) in which ultrafine grains are introduced into a material through intense plastic straining [1]. In practice, ECAP appears to have greater utility than HPT because there is a potential for scaling-up theprocessfor industrial applications through procedures suchas thedevelopment V.P.Astakhov(&) GeneralMotorsBusinessUnitofPSMi,1792ElkLn,Okemos,MI48864,USA e-mail:[email protected] ©SpringerInternationalPublishingSwitzerland2015 1 J.P.Davim(ed.),ModernManufacturingEngineering,MaterialsForming, MachiningandTribology,DOI10.1007/978-3-319-20152-8_1