advanced machining processes of metallic materials theory modelling and applications second edition pdf

ADVANCED MACHINING
PROCESSES OF METALLIC
MATERIALS

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ADVANCED MACHINING
PROCESSES OF METALLIC
MATERIALS
Theory, Modelling, and Applications
Second Edition

WIT GRZESIK
Professor of Mechanical Engineering, Faculty of Mechanical
Engineering, Opole University of Technoloy, Poland

AMSTERDAM • BOSTON • HEIDELBERG • LONDON
NEW YORK • OXFORD • PARIS • SAN DIEGO
SAN FRANCISCO • SINGAPORE • SYDNEY • TOKYO

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Elsevier
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PREFACE
The broad subject of manufacturing engineering and technology, including machining
technology, continues to be recognized as an important and distinct area of study at
mechanical engineering faculties of universities and various technical and research
institutes. After a couple of decades of neglect, this production subject has finally
acquired the distinct academic stature and significance. Engineers and students have
come to the conclusion that without a sound manufacturing base, no nation can hope
for economic survival in an increasingly competitive international marketplace.
This book is an exploration in modern machining technology. In addition to providing basic information on metal cutting processes and operations, this book also describes
the level of modern machining technology, adopted, to varying degrees, by different sectors of industry in general. Metal machining/cutting is a dynamic technology, involving
the range of disciplines of science, which must be mastered to become a practitioner of
advanced machining technology. Some of these disciplines are the province of machining
technologists, others concern both cutting tool and machine tool manufacturers, and
machine tool builders and users. Nonetheless, it can be helpful for all machining-related
businesses to have a good grasp of the relevant issues in each area. The eight disciplines
are as follows, each of which is covered in relevant clusters of chapters:
• Materials engineering (see chapters: Cutting Tool Materials; Machinability of
Engineering Materials)
• Engineering mechanics and related disciplines (see chapters: Orthogonal and
Oblique Cutting Mechanics; Chip Formation and Control; Cutting Vibrations)
• Thermodynamics (see chapters: Heat in Metal Cutting; Tool Wear and Damage;
and partially chapter: Cutting Fluids)
• Tribology (see chapters: Tribology of Metal Cutting; Tool Wear and Damage; and
partially chapter: Cutting Fluids)
• Modelling techniques (basically chapters: Modelling and Simulation of Machining
Processes and Operations and successively chapters: Orthogonal and Oblique Cutting

Mechanics; Chip Formation and Control; Cutting Vibrations; Heat in Metal Cutting;
Cutting Fluids; Tribology of Metal Cutting; Tool Wear and Damage; Machinability of
Engineering Materials; Machining Economics and Optimization)
• Manufacturing engineering (see chapter: Advanced Machining Processes and
appropriate sections involved)
• Process and motion control (see chapters: Chip Formation and Control; SensorAssisted Machining; Virtual/Digital and Internet-Based Machining; and partially
chapter: Advanced Machining Processes)
• Surface engineering (see chapter: Surface Integrity)

ix

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Preface

x

In general, this book is structured into three parts: the first, including Chapter: 2,
Metal Cutting Operations and Terminology; Chapter 3: Trends in Metal Cutting
Theory and Practice; Chapter 4, Cutting Tool Materials; Chapter 5, Modelling and
Simulation of Machining Processes and Operations; Chapter 6, Orthogonal and
Oblique Cutting Mechanics; Chapter 7, Chip Formation and Control; Chapter 8,
Cutting Vibrations; Chapter 9, Heat in Metal Cutting; Chapter 10, Cutting Fluids;
Chapter 11, Tribology of Metal Cutting; Chapter 12, Tool Wear and Damage;
Chapter 13, Machinability of Engineering Materials; Chapter 14, Machining
Economics and Optimization, provides fundamentals of the machining process; the
second, including Chapter 15, Advanced Machining Processes; Chapter 16,
Micro-Machining; Chapter 17, Nanomanufacturing/Nanotechnology; Chapter 18,
Sensor-Assisted Machining; Chapter 19, Virtual/Digital and Internet-Based

Machining, overviews the effects of the theoretical and experimental considerations in
high-level machining technology; and the third Chapter 20, Surface Integrity,
summarizes production outputs related to surface integrity and part quality.
Numerous colour images are provided to facilitate the comprehension of the physical
phenomenon involved and the developments of cutting tools, machine tools and
machine control systems.
Numerous references are provided for more detailed or more extensive information on various aspects of metal cutting and its effective applications ranging from
mezo- to nano-scale.
In particular, I have recommended the following books (in alphabetic order) to be
good sources of additional information for metal cutting process and their optimal
applications:
G. Boothroyd, W.A. Knight, Fundamentals of Machining and Machine Tools,
CRC Press, Boca Raton, 2006, is an exceptional source of descriptions of various
cutting-oriented phenomena an recent advances in conventional and nonconventional
machining processes.
T.H.C. Childs, K. Maekawa, T. Obikawa, Y. Yamane, Metal Machining. Theory and
Applications, Arnold, London, 2000, is a good source for reliable experimental data and
modelling techniques (slip-line, FEM, AI-based) developed mainly in UK and Japan.
M.C. Shaw, Metal Cutting Principles, Clarendon Press, Oxford, 1989, is a good
source for scientific interpretation of physical principles of conventional machining
processes based on classical mechanics, strength of materials and tribology.
H.K. Toănshoff, B. Denkena, Basic of Cutting and Abrasive Processes, Springer,
Heidelberg, 2013, is a new reference devoted to available technology of metal cutting
and abrasive processes and their effective implementation in the contemporary industrial practice.

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Preface

xi

E.M. Trent, P.K. Wright, Metal Cutting, Butterworth Heinemann, Boston, 2000,
is a unique source for both traditional material-based approach to the metal cutting
phenomena and essential aspects of 21st-century manufacturing.
According to the author’s intention, this book is addressed to those studying and
teaching the principles of machining processes and operations at universities, as well as
providing an updated theoretical and applied knowledge for those involved in the
machining/manufacturing industry.
I am very grateful to all of those companies (cited by name or reference number
in the figure legends and table footnotes) that granted permission for reproduction of
numerous figures and tables.
˙
I express my gratitude to my coworker Dr. K. Zak
for his invaluable help in
preparation illustrations and graphics. Finally and most importantly, I thank my family
for its patience during the many times when my preoccupation with this book
inconvenienced them.
W. Grzesik
July 2016

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NOMENCLATURE

LATIN SYMBOLS
A
Aa
Ac

Am
Ar
Ash
Aα
Aγ
ae

af

ap

apl
apu
av
B
Be

shape factor in Shaw’s equation for heat partition
apparent area of contact between two surface; average value of shape
factor A
cross-sectional area of the uncut chip, i.e., the cross-sectional area of
the layer of material being removed by one cutting edge measured
normal to the resultant cutting direction; contact area
maximum value of shape factor A
real area of contact between two surfaces
area of shear plane
tool flank, i.e., the surface over which the surface produced on the
workpiece passes
tool face, i.e., the surface over which the chip flows

working engagement, i.e., the instantaneous engagement of the
complete tool with the workpiece, measured in the working plane
Pfe and perpendicular to the direction of feed motion (previously
known as depth of cut in a slab-milling operation)
feed engagement, i.e., the instantaneous engagement of the tool
cutting edge with the workpiece, measured in the working plane Pfe
and in the direction of feed motion (in single-point machining
operations it is equal to the feed f; in multipoint tool operations, it
is equal to the feed per tooth)
back engagement, i.e., the instantaneous engagement of the complete tool with the workpiece, measured perpendicular to the working plane Pfe (previously known as depth of cut in a single-point
tool operation and width of cut in a slab-milling operation)
lower limit of depth of cut (doc)
upper limit of doc
amplitude of vibration
groove width in a groove tool; zone where the flank is regularly
worn
equivalent groove width in a groove tool

xiii

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Nomenclature

xiv
BL
BW
b
bcr

blim
C
CT1, CT2, CT3
Cv
Cm
Cmat
Cmin
Cmt
Cpr
Cv
Ct
CT
c
cd
cp
D
dF
E
Ec
Ef
Ep
Esh
Efα
Efγ
e
ec
efγ
esh
F
F(t)

Fa
Fc

length of groove backwall wear
width of groove backwall wear
width of cut; width of the cutting edge
the lowest blim obtained for the phasing most favourable for chatter
generation
limiting stable axial depth of cut
constant in upper boundary prediction for the shear angle by Oxley,
constant in Shaw’s equation
constant in general tool-life equation
cutting speed for 1 min of tool life (in m/min)
cost of machining, neglecting non-productive costs
cost of material for one workpiece
minimum cost of production, i.e., the minimum value of Cpr
total machining cost
production cost, i.e., the average cost of producing each component
on one machine tool
constant in the inverse Taylor equation equal to the cutting speed
for T 5 1 min
constant in the original Taylor tool-life equation
constant in the Taylor equation equal to T for vc 5 1 m/min
rigidity constant
damping force per unit velocity, i.e., the viscous damping constant
specific heat capacity
tool diameter (e.g. drill or milling cutter)
variation in the cutting force
Young’s modulus; process activation energy
cutting energy

energy required to perform feed motion; friction energy
energy required to perform plastic deformation
energy required to perform shearing
energy required to overcome friction on the flank face
energy required to overcome friction on the rake face
base of natural logarithm
specific cutting energy
specific friction energy related to the rake face
specific cutting energy related to shearing
resultant cutting force
periodic force (in function of time)
active force
cutting component of the resultant tool force, Fr

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Nomenclature

FcN
Fdyn
Ff
Fm
Fo
Fo
Fp
Fr
Fsh
FshN
Fsu

Fα
FαN
Fγ
FγN
f

fm
fmax
fl
fn
fnd
fopt
fu
fz
HT
HW
HRC
HSC
h

hch
hcmin
hcmax
Im[G]
K

xv

an asymptotic value of the cutting force Fc
force component due to chip deformation in HSC

feed force
momentum force
Fourier number
objective function
ploughing force
resultant tool force
force required to shear the work material on the shear plane
force perpendicular to the shear plane
resultant shear force in HSC
tangential force on the flank face
force perpendicular to flank face
frictional force on the tool face; frictional force between sliding
chip and tool
force perpendicular to the rake face
feed rate, i.e., the displacement of the tool relative to the workpiece,
in the direction of feed motion, per revolution of the workpiece or
tool
feed per minute
maximum available machine feed
lower limit of feed
resonance of frequency
natural damped frequency of the system
optimum value of feed
upper limit of feed
feed per tooth
hardness of the tool material
hardness of the workpiece material
Rockwell hardness number (C scale)
high spot count (count(s)) (see also High Speed Cutting)
uncut chip thickness, i.e., the thickness of the layer of material being

removed by one cutting edge at the selected point measured normal
to the resultant cutting force direction
chip thickness
mean uncut chip thickness, i.e., the mean value of hc
maximum uncut chip thickness, i.e., the maximum value of hc
imaginary part of the FRF
constant for a machining operation; can be regarded as the distance
travelled by the tool in relation to the workpiece during the
machining time tm.

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Nomenclature

xvi
K1ÀK8
[K]
KB
KE
KF
KM
KT
K1C
k
kc
kh
L
l
lc

lca
lcr
le
lm
lnc
lp
lsh
lsl
lst
lt
lw
M
Mt
MR
Mr1
Mr2
Mt
0

Mt
MT1ÀMT5
m

constant in LPM
global stiffness matrix
distance from the cutting edge to the back crater contour
radial displacement of the tool corner
width of the land between the crater and cutting edge
distance from the cutting edge to the deepest crater point
crater depth; depth of groove backwall wear

fracture toughness
shear stress in the slip-line field; constant in the Stabler’s formula;
damping ratio; negative slope of the tool-life curve
specific cutting pressure
chip thickness compression ratio (also Λh)
tool length; cutting length; lay (surface texture)
land length in a grooved tool
natural tool-chip contact length
length of the active cutting edge
restricted tool-chip contact length
equivalent restricted contact length
length of machined surface
natural contact length
length of the plastic contact
length of shear plane (also lAB)
sliding-contact length
sticking-contact length
length of tool
length of workpiece or hole to be machined; length of cut path or
cut surface
total machine and operator rate (cost per unit time), including
machine depreciation
operator’s Wo and machine and operator overheads; mean line (M)
system
machinability rating
upper material ratio (%)
lower material ratio (%)
machine-tool depreciation rate (cost per unit time)
machine-tool rate including overheads (cost unit time)
extreme finishing; finishing; semi-roughing, roughing and heavy

roughing machining operations
slope of linear plastic stressÀstrain relation; relative shear stress in
Rowe and Spick’s model; mass of the vibration system; width of the
contact zone

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Nomenclature

mavg
mch
m1
N
Nb
Nt
NL1
NL2
NW1
NW2
NT
n
nopt
ns
nsc
nsef
nsp
nt
nw
P

{P}
Pc
Pe
Pec
Pf
Pfe
Pg
Pm
Pn
Po
Pp
Ppe

xvii

average number of teeth in the cut
mass of chip specimen
strain rate sensitivity exponent
number of teeth on the cutting tool; number of full waves; nose
wear
batch size, i.e., the number of components in the batch to be
machined
number of tools used in machining the batch of components
notch wear length on main cutting edge
notch wear length on secondary cutting edge
notch wear width on main cutting edge
notch wear width on secondary cutting edge
thermal number; number of tool changes necessary during the
machining of a batch of components
strain-hardening index or exponent; constant in Taylor’s tool-life

equation; spindle rotation speed
optimum value of rotational speed
rotational frequency of a machine-tool spindle
rotational frequency of a machine-tool spindle for minimum
production cost
rotational frequency of a machine-tool spindle for minimum
efficiency (maximum profit rate)
rotational frequency of a machine-tool spindle foe minimum
production time
rotational frequency of the cutting tool or abrasive wheel
rotational frequency of workpiece
power
vector of all applied loads
local peak count (count/cm) (also cutting power)
electrical power consumed by the machine tool during a machining
operation
Peclet number
assumed working plane
working plane
tool-face orthogonal plane
power required to perform the machining operation
cutting edge normal plane
tool orthogonal plane
tool back plane
working back plane

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Nomenclature

xviii
Pr
Pre
Ps
Pse
Psh
pA
ps
Q
Q1
Q2
Q3
Q4
QW
qc
qt
qw
q_
R
{R}
Ra
Rc
Rch
Rk
Rku
RKF
Rmin(τ)
Rmr(c)
Ro

Rp
Rpk
Rq
RR
Rsk
Rsm
RSH
Rt
Rv
Rvk

tool reference plane, the rate of production
working reference plane
tool cutting edge plane
working cutting edge plane
shear plane
hydrostatic pressure in point A at the free surface
specific cutting power, i.e., the work required to remove a unit
volume of material
total amount of heat generated in machining
heat source due to plastic deformation
frictional heat source
heat source at the contact between the workpiece and the flank
heat source from which a small part of heat is transferred to the
sub-surface layer
volumetric material removal rate
heat flux flowing to the chip
heat flux flowing to the tool
heat flux flowing to the workpiece
heat flow rate

thermal number; universal gas constant; surface roughness
load vector
arithmetical mean value of surface roughness (CLA)
Rockwell hardness number (C scale)
heat partition coefficient, i.e., percentage of heat entering the chip
core roughness depth
kurtosis
heat partition coefficient defined by Kato and Fujii
minimum radius of up-curling
material ratio at depth ‘c’
groove radius
maximum height of peaks
reduced peak height
root mean square (RMS) average
heat partition coefficient defined by Reznikov
skew (skewness)
average peak spacing
heat partition coefficient defined by Shaw
total height of the profile (obsolete Rmax)
maximum depth of valleys
reduced valley depth

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Nomenclature

Rz
Rzt
RΔa

RΔq
Rλa
Rλq
rmin
rc
rchip
rn
rs
ru
rui
ruf
rε
S
Sa
S’
SD
SL
SW
s
T
T
Te
Tm
To
Tmod
Tp
TR
Tr
t
ta

tc
tcs
te
td
tl

xix

maximum height of the profile
theoretical value of PÀV parameter
centre line average (CLA) slope (deg)
RMS slope (deg)
CLA wavelength
RMS wavelength
radius of the cutting edge at which cutting is taking place
cutting ratio
radius of the chip curvature
radius of the cutting edge
side-curling radius
up-curling radius; chip curvature
radius of initial chip curl
radius of final chip curl
corner radius, i.e., the radius of a rounded tool corner
tool major cutting edge; income per component
active cutting edge
tool minor cutting edge
depth of secondary face wear
sampling length
width of secondary face wear
lamellar spacing

temperature; absolute temperature; tool life
average tool life
economic tool life (also TE)
melting temperature
reference temperature
velocity modified temperature
tool life for maximum production rate (also TQ)
reference tool life
room (ambient) temperature; tool life for a cutting speed of vr
time
acceleration time
tool changing time, i.e., the average machine time to change a
worn tool or to index (and, if necessary, replace) a worn insert
interchange time
magazine indexing (travelling) time
deceleration time
non-productive time, i.e., the average machine time to load and
unload a component and to return the cutting tool to the beginning
of the cut

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Nomenclature

xx
tl
tm
tmax
tpr

tr
tx
{U}
{u}
Vw
VBB
VBBmax
VBC
VBN
Vm.
VN
VB 0
vac
vc
vcc
vce
vch
vcp
vcR
vcT
vcTmax
ve

vef
vf
vHSC
vmax
vmin
vp

loading and unloading time
machining time, i.e., machine time to machine a component
maximum operation time
production time, i.e., the average time to produce one component
on one machine tool
transportation (approach) time per workpiece
rapid travel location time
matrix of nodal velocities
displacement vector
volume of tool material lost due to wear
average width of flank wear land in the central portion of the active
cutting edge
maximum width of flank wear land in the central portion of the
active cutting edge
width of flank wear at tool corner
width of notch wear
volume of material removed in machining
width of the flank wear land at the wear notch
wear of minor flank face
mean cutting speed, i.e., the average value of v along the major
cutting edge
cutting speed, i.e., the instantaneous velocity of the primary motion
of the selected point on the cutting edge relative to the workpiece
optimum cutting speed for minimum production cost
cutting speed at minimum cost
chip velocity
optimum cutting speed for minimum production time
reference cutting speed in tool-life equation for grooved tool
cutting speed corresponding to defined tool life T
cutting speed corresponding to maximum tool life Tmax

resultant cutting speed, i.e., the instantaneous velocity of the
resultant cutting motion of the selected point on the cutting edge
relative to the workpiece
cutting speed for maximum efficiency (maximum rate of profit)
feed velocity
UTS-depending cutting speed in HSC
maximum cutting speed, i.e., maximum of vc
minimum cutting speed, i.e., minimum of vc
cutting speed for minimum production time

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Nomenclature

vpo
vr
vs
vchsl
vchst
W
Wc
Wg
w
X1
X2
x

xxi

cutting speed when maximum power is used
cutting speed giving a reference tool life of Tr
shearing velocity; sliding velocity
chip velocity along the sliding region
chip velocity along the sticking region
weight of workpiece; waviness
tool coating effect factor
chip-groove effect factor
width of cut
coded value of speed in LPM
coded value of feed in LPM
distance from the point of chip separation

GREEK SYMBOLS
α
αe
αn
αne
αT
αW
β
χ
Γ
γ
γ AB
γ EF
γc
γe
γf
γ f1

γ f2
γg
γh
γn
γ ne

alpha-phase, thermal diffusivity
thermal expansion coefficient
tool normal clearance
working normal clearance
thermal diffusivity of the tool material
thermal diffusivity of the workpiece material
proportion of heat conducted into the workpiece; beta-phase
characteristic of contact length in Rowe and Spick’s model
proportion of heat generated in primary deformation zone
conducted into workpiece
gamma-phase
strain on shear plane in Oxley’s model
shear strain along the exit boundary EF in Oxley’s model
catastrophic shear strain
effective rake angle (also γ ef and γ eff)
tool side rake angle
tool side rake angle in the land
tool side rake angle in the groove
tool geometric rake angle (direction of the maximum slope of the
rake)
homogenous shear strain
tool normal rake
working normal rake

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Nomenclature

xxii
γo
γp
γ sb
γ sh
γ_ sh
rT
Δx
Δt
Δs
Δs2
ΔΘf
δu
δv
ε
εb
εmax
εp
εp
p
εeff
εpo
ε_ p
ε_ po
ε_ 0p

εr
εre
η

ηb
ηc
ηs
θ
θint
θfmax
θmax
θn

tool orthogonal rake
tool back rake
total shear strain in the shear band (sb)
shear strain
shear strain rate
local temperature gradient (Hamilton’s vectoral operator-nabla) in
Km21
thickness of the shear zone (band)
time elapsed for material element to travel a distance Δs
distance along the shear plane
thickness of the shear zone in Oxley’s model
mean temperature rise due to friction
response (deflection) in the u direction
response (deflection) in the v direction
uniaxial true strain; fraction of waves
chip strain caused by bending
chip strain at fracture

the equivalent strain
accumulated plastic strain
effective plastic strain
reference plastic strain
equivalent strain rate
reference plastic strain rate
strain rate equal to 1.0 s21
tool-included angle
working included angle
resultant cutting speed angle, i.e., the angle between the direction of
primary motion and the resultant cutting direction; angle between
the texture line and the shear plane; contact length factor
chip back-flow angle
chip flow angle; angle of maximum slope of the rake angle
chip side-flow angle
temperature, mean angle of friction on tool face; groove tangent
angle
temperature at tool-chip interface
maximum temperature rise of material passing through the
secondary deformation zone
maximum interface temperature along the rake face (also tmax)
mean angle of friction measured in the normal plane

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Nomenclature

θsmax
θo

Θ(T)
Θs
Θt
κr
0
κr
κre
κ0re
λ
λT
λW
λs
λse
μ
μa
μc
μcmax
μm
μRe[G]
ν
ρ
σ
1σ
2σ
σ
σc
σcmax
σc
σf
σn

σnmax
σo
σsh
σT
τ
τc

xxiii

maximum shear-plane temperature (maximum temperature rise of
material passing through the primary deformation zone)
initial workpiece temperature
thermal softening factor
mean shear-plane temperature
average interface temperature
tool cutting edge angle
tool minor cutting edge angle
working cutting edge angle
working minor cutting edge angle
thermal conductivity
thermal conductivity of the tool material
thermal conductivity of the workpiece material
tool cutting edge inclination
working cutting edge inclination
coefficient of friction, viscosity
adhesion component of coefficient of friction
equivalent coefficient of friction
maximum coefficient of friction
mechanical component of coefficient of friction
real part of the FRF

coefficient of tool-life variability
density of work material
uniaxial true stress
tensile residual stress
compressive residual stress
effective von Misses stress
normal contact stress acting on the toolÀchip interface
maximum normal contact stress acting on the toolÀchip interface
mean value of normal contact stress
flow stress; fracture stress
normal stress on the tool face
maximum normal stress on the tool face
initial yield stress at the reference temperature To; constant in
uniaxial true strain relationship
normal stress on the shear plane (also σs)
standard deviation
chip flow angle
shear contact stress acting on the toolÀchip interface

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Nomenclature

xxiv
τc

mean value of shear contact stress
shear flow stress at zero plastic strain in Oxley’s model
shear stress on the shear plane

shear flow stress of the work material
shear stress on the tool face in the sticking region
shear stress in the shear plane with zero normal stress applied
shear angle
shear angle in the normal plane Pn
shear angle for unstrained (softer) material
shear angle calculated from mechanical properties of the workpiece
material
angular frequency of vibration; angle between the resultant cutting
force and the shear plane
angular frequency of external harmonic force
natural angular frequency

τo
τs
τ sh
τ st
τ so
Φ
Φn
Φo
ΦT
ω
ωf
ωn

ABBREVIATIONS
AC
ACC
ACO

A/D
ADF
ADI
AE
AFM
AFRP
AGV
AI
AJM
ALE
Al2O3
AMPR
AMZ
ANN
ANSI
APL
APS

Adaptive control; air cooled
Adaptive control constraint
Adaptive control optimization
Analog-to-digital converter
Amplitude distribution function
Austempered ductile iron
Acoustic emission
Abrasive-flow machining; atomic force microscopy
Aramid fibre reinforced plastic
Automated guided vehicle
Artificial intelligence
Abrasive-jet machining

Arbitrary LagrangianÀEulerian formulation
Aluminium oxide, white ceramics
Advanced Manufacturing Research Program
Altered material zone
Artificial neural network
American National Standards Institute
A programming language
Advanced process system

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Nomenclature

AR
ARMD
ASM
ATC
BAC
BEM
BHN
BUE
bcc
CAD
CAE
CAM
CAPP
CAT
CAVE
CBGF

CBN
CBN-HT
CCD
CCI
CE
CF
CFEST
CFRP
CGI
CIM
CIRP
CLA
CM
CMM
CNC
COS
CT
CVD
CVL
DARPA
DBGF
DBTT
Dc
DLC

xxv

Autoregression
Area-restricted molecular dynamics
American Society for Metals (now ASM International)

Automatic tool changer
Bearing area curve
Boundary element method
Brinell hardness number (see HB)
Built-up-edge
Body-centred cubic
Computer-aided design
Computer-aided engineering
Computer-aided manufacturing
Computer-aided process planning
Computer-aided testing
Computer Automated Visualization Environment
Circular thread-milling tool
Cubic boron nitride
CBN hard turning
Charge-coupled device (camera)
Coherence correlation interferometry
Concurrent engineering; control emulator
Cutting fluid
Cutting Fluid Evaluation Software Testbed
Carbon-fibre reinforced plastic
Compacted graphite iron
Computer-integrated manufacturing
International Institution for Production Engineering Research
Centre-line average
Communication medium
Coordinate measuring machine
Computer numerical control
Computerized optimization system
Cermet

Chemical vapour deposition
Copper vapour laser
Defence Advanced Research Project Agency
Direct circular thread-milling tool
Ductile-to-brittle transition temperature
Diameter of cutter
Diamond-like coating

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Nomenclature

xxvi
DLL
DM
DN
DNC
DPU
DRIE
DSC
DSP
DUV
DVA
EBM
ECG
ECM
ECT
EDM
EDG

EDX
EL
ELACM
ELID
EMF
EP
Ew1;Ew2
e-manufacturing
e-work
FDA
FDM
FEA
FEM
FES
FFT
FIB
FMS
FOF
FRF
FRP
FTP
fcc
GAC

Dynamic link library
Digital manufacturing
Product of the spindle diameter in mm and the spindle speed in
rpm
Direct numerical control; distributed numerical control
Data processing unit

Deep reactive ion etching
Differential scanning calorimeter
Digital signal processing
Deep ultraviolet lithography
Dynamic vibration absorber
Electron-beam machining
Electrochemical grinding
Electrochemical machining
Effective chip thickness
Electrical discharge machining
Electro-discharge grinding
Energy dispersion X-ray
Evaluating length
Eximer laser-assisted chemical machining
Electrolytic in-process dressing
Electromotive force (also emf)
Extreme pressure
Offsets in turn-milling operations
Electronic-manufacturing
Electronic-work
Finite different approach
Finite different method
Finite element approach (analysis)
Finite element method
Fuzzy expert system
Fast Fourier transform
Focused ion beam (micromachining)
Flexible manufacturing system; Federation of Materials Societies
Factory of the future
Frequency response function

Fiberglass-reinforced plastic
File transfer protocol
Face-centred cubic
Geometric adaptive control

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Nomenclature

GFRP
GGG
HB
HEM
Hi-E
HK
HK100
HM
HMC
HMI
HPC
H-PCBN
HPC
HPDL
HPM
HPMA
HPPA
HPRA
HR
HSM

HSC
HSS
HSS-Co
HT
HTML
HV
HVM
hcp
ICM
ID
IMM
IMS
I/O
IPM
IR
IT
ITC
JC

xxvii

Graphite-fibre reinforced plastic; glass-fiber reinforced plastic
Nodular cast iron (German equivalent to CGI; see CGI)
Brinell hardness number
High efficiency machining
High efficiency machining (range)
Knoop hardness number
Knoop hardness using 100g load
Hard machining, hard milling
Horizontal machining centre

HumanÀmachine interface
High pressure coolant (supply)
High content PCBN
High performance cutting
High power diode laser
High performance machining; hard part machining
High precision motorised arm
High precision pull-down arm
High precision removable arm
Rockwell hardness number, including scales such as HRA, HRB,
HRC, etc.; hot rolled
High speed machining
High speed cutting
High speed steel
Cobalt enriched high speed steels
Hard turning
Hyper Text Markup Language
Vickers hardness number
High velocity machining
Hexagonal close-packed
Iterative convergence method
Inside diameter
Intelligent machining module
Intelligent manufacturing system, intelligent maintenance system
Input/output
Inductive probe module
Infrared (e.g. camera, pyrometer)
Information technology; intelligent tool
Intelligent thermal control
JohnsonÀCook material model

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Nomenclature

xxviii
JIT
KHN
LAM
LAN
LASER
LBM
LCD
LFM
LDF
LIGA
LN
LODTM
LPM
L-PCBN
MCD
MC-HT
MCU
MD
MDB
MDC
MDI
MEMS
MES

MMC
MO
MQC
MQL
MQCL
MRP
MRR
MST
MTM
MVL
mMT
NC
NEMS
NDT
NGM
NNI

Just-in-time
Knoop hardness number (obsolete; see HK)
Laser-assisted machining
Local area network
Light amplification by stimulated emission of radiation
Laser-beam machining
Liquid crystal display
Laser flash method
Linear discriminant function
Photo-lithography and electroplating method
Liquid nitrogen
Large optics diamond turning machine
Linear programming method

Low-content PCBN
Machine code data
Mixed ceramics hard turning
Machine control unit
Molecular dynamics
Machinability database
Machinability Data Centre
Manual data input
Micro-electromechanical system
Manufacturing execution system
Metal matrix composite
Mineral oil
Minimum quantity cooling
Minimum (minimal) quantity lubrication
Minimum quantity cooling lubrication
Material requirements planning
Material removal rate
Microsystems technology
Multitasking machining
Minimum volume lubrication
Micro/mezzo-scale machine tool
Numerical control
Nano-electromechanical system
Non-destructive testing; nil ductility transition
New generation manufacturing
National Nanotechnology Initiative

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Nomenclature

NPT
OD
OFHC
PAC
PACVD
PAM
PC
PCB
PCBN
PCD
PDZ
PGI
PH
PKM
PLC
PLM
P/M
PSZ
PVD
QA
QC
RCF
RCT
RF
RMI
RMS
RNS
RP

SDZ
SiC
Si3N4
SL or SLA
SLF
SLS
SMS
SMART
SPDT
SPM
STM
TAM

xxix

Non-productive times
Outside diameter
Oxygen-free, high conductivity (for copper)
Plasma-arc cutting
Plasma-assisted CVD (coating deposition technique)
Plasma-assisted machining
Personal computer; printed circuit; polycarbonate
Printed circuit board
Polycrystalline cubic boron nitride
Polycrystalline diamond
Primary deformation zone
Phase grating interferometer
Precipitation hardenable (steel)
Parallel kinematic machine
Programmable logic controller

Product lifecycle management
Powder metallurgy
Partially-stabilized zirconia
Physical vapour deposition
Quality assurance
Quality control
Rolling contact fatigue
Restricted-contact tool
Radio frequency
Radio machine interface
Root-mean-square (also rms)
Remote notification system
Rapid prototyping
Secondary deformation zone
Silicon carbide
Silicon nitride, nitride ceramics
Stereolithography technique; sampling length
Slip-line field
Selective lased sintering
Short message service
Smart Assistant to Machinists
Single-point diamond turning
Scanning probe microscopy
Scanning tunnelling microscope
Thermally assisted machining

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Nomenclature

xxx
TAHMP
TCM
TDZ
TFTs
TiAlN
TiC
Ti(C,N)
TiN
TMP
TMS
TQC
TQM
TRS
UAM
UCL
UCT
UF
UHSM
UM
UR
UTS
UV
UVC
VED
VLSI
VM
VMC
VR

WAP
WC
WEDG
WIP
WWW
XML
Y
ZD

Thermally assisted hybrid machining process
Tool condition monitoring
Tertiary deformation zone
Thin film thermocouple sensor
TitaniumÀaluminium nitride
Titanium carbide
Titanium carbo-nitride
Titanium nitride
Total machining performance
Tool monitoring system
Total quality control
Total quality management
Tensile rupture strength
Ultrasonic-assisted machining
Upper control limit
Uncut/undeformed chip thickness
Ultra fine (e.g., carbide grade)
Ultra-high speed machining
Ultrasonic machining
Unit removal
Ultimate tensile strength (also Rm)

Ultraviolet
Ultrasonic vibration cutting
Video edge detection
Very large-scale integration
Virtual manufacturing
Vertical machining centre
Virtual reality
Wireless Application Protocol
Sintered tungsten carbide (equivalent to HM in German)
Wire electro-discharge grinding
Work in progress
World Wide Web
Extensive Markup Language
Yield strength
Zero defect (manufacturing)

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