Hybrid Machining: Theory, Methods, and Case Studies

Description

Hybrid Machining: Theory, Methods, and Case Studies covers the scientific fundamentals, techniques, applications and real-world descriptions of emerging hybrid machining technology. This field is advancing rapidly in industrial and academic contexts, creating a great need for the fundamental and technical guidance that this book provides. The book includes discussions of basic concepts, process design principles, standard hybrid machining processes, multi-scale modeling approaches, design, on-machine metrology and work handling systems. Readers interested in manufacturing systems, product design or machining technology will find this one-stop guide to hybrid machining the ideal reference. Cover Front-matter_2018_Hybrid-Machining Hybrid Machining Copyright_2018_Hybrid-Machining Copyright Contents List-of-Contributors_2018_Hybrid-Machining List of Contributors Short-Biographies_2018_Hybrid-Machining Short Biographies Preface_2018_Hybrid-Machining Preface Chapter-1---Introduction-to-Hybrid-Machining-Technology_2018_Hybrid-Machinin 1 Introduction to Hybrid Machining Technology 1.1 Overview of Machining Technology 1.1.1 Introduction to Machining Processes 1.1.2 Advances and New Challenges 1.2 Concept, Definition, and Classification of Hybrid Machining Processes 1.3 Major Elements of Hybrid Machining Technology 1.3.1 Hybrid Machine Tools 1.3.2 Hybrid Tooling 1.3.3 Hybrid Machining Processes 1.3.4 Metrology System 1.3.5 Work Handling System 1.3.6 Process Modeling Technique 1.4 Benefits of Hybrid Machining Technology 1.5 Challenges and Opportunities 1.6 Concluding Remarks 1.6.1 Development of Specific Multiaxis Hybrid Machine Tools 1.6.2 Opportunities for Improving Process Monitoring Techniques 1.6.3 Development of On-Machine Tool Fabrication and Metrology Techniques 1.6.4 Establishment of Novel Processes 1.6.5 Cost-Effectiveness Study 1.6.6 Industrial Implementation References Chapter-10---On-Machine-Metrology-for-Hybrid-Machining_2018_Hybrid-Machining 10 On-Machine Metrology for Hybrid Machining 10.1 Introduction 10.2 Surface Metrology 10.3 Optical Methods of On-Machine Surface Metrology 10.3.1 Criteria for the Development of On-Machine Optical Surface Metrology System 10.3.2 Challenges From Offline to On-Machine Metrology 10.4 Case Study: On-Machine Measurement Using Dispersed Reference Interferometry 10.4.1 Dispersed Reference Interferometry 10.4.1.1 Principle of DRI 10.4.1.2 DRI System Design 10.4.1.3 DRI Principle of Operation 10.4.1.4 DRI System Specification 10.4.2 Machine Tool Calibration 10.4.3 DRI On-Machine Calibration 10.4.3.1 On-Machine Vibration Test 10.4.3.2 Machine Tool Kinematic Error Compensation 10.4.3.3 Amplification Coefficient and Linearity Error Correction 10.4.4 Application of DRI to Diamond Turning Machine 10.5 Summary References Chapter-11---Multiscale-Modeling-of-Hybrid-Machining-Pro_2018_Hybrid-Machini 11 Multiscale Modeling of Hybrid Machining Processes 11.1 Introduction 11.2 Multiscale Modeling Fundamentals 11.2.1 Basics of Multiscale Modeling Technology 11.2.2 Multiscale Modeling Methodologies and Strategies 11.2.2.1 Sequential Multiscale Modeling 11.2.2.2 Concurrent Multiscale Modeling 11.2.3 Modeling and Simulation Approaches for Machining Processes 11.2.3.1 Finite Element Method Modeling 11.2.3.2 Molecular Dynamics Modeling 11.2.3.3 Multiscale Modeling 11.3 Multiscale Modeling for Laser-Assisted Hybrid Machining Processes 11.3.1 Process Work Principle and Features 11.3.2 Multiscale Modeling Considerations for Laser-Assisted Hybrid Machining 11.3.3 Pre- and Postprocessing 11.4 Case Study-Multiscale Modeling for Laser-Assisted Machining of Mold Steel 11.4.1 Material Properties and Constitutive Model 11.4.2 Boundary Conditions and Assumptions 11.4.3 Results and Discussions 11.4.4 Conclusions 11.5 Concluding Remarks References Chapter-2---Overview-of-Hybrid-Machining-Processes_2018_Hybrid-Machining 2 Overview of Hybrid Machining Processes 2.1 Introduction 2.2 Design Principle and Methodology for Hybrid Machining Processes 2.3 Assisted Hybrid Machining 2.3.1 Vibration-Assisted Machining 2.3.2 Laser-Assisted Machining 2.3.3 Magnetic Field-Assisted Machining 2.3.4 External Electric Field-Assisted Machining 2.3.5 Fluid-Assisted Machining 2.4 Combined Hybrid Machining 2.4.1 Electrochemical Discharge Machining 2.4.2 Electrochemical Grinding 2.4.3 Electrodischarge Grinding and Abrasive-EDM Processes 2.4.4 Laser-Chemical/Electrochemical Machining 2.4.5 Laser-Waterjet Machining 2.4.6 Mechano-Electrochemical Machining 2.4.7 Abrasive-Waterjet Milling 2.5 Combination of Controlled Processes 2.5.1 Grind Hardening 2.6 Summary References Chapter-3---Laser-Assisted-Machining_2018_Hybrid-Machining 3 Laser-Assisted Machining 3.1 Introduction 3.2 Laser-Assisted Machining Processes 3.2.1 Laser-Assisted Turning 3.2.2 Laser-Assisted Milling/Grinding 3.2.3 Laser-Assisted Jet Electrochemical Micromachining 3.2.4 Laser-Assisted Waterjet Machining 3.2.5 Summary of Laser-Assisted Machining Processes 3.3 Laser Sources for Laser-Assisted Machining 3.4 Thermal Modeling 3.5 Process Control and Optimization 3.6 Characteristics of Laser-Assisted Machining of Hard-to-Machine Materials 3.6.1 Metals 3.6.1.1 Titanium Alloys 3.6.1.2 Nickel-Based Super Alloys 3.6.1.3 Ion-Based Difficult-to-Machine Materials 3.6.1.4 Ceramics 3.6.1.5 Composites 3.7 Case Study—Laser-Assisted Grinding of Ceramics 3.7.1 Laser Source for Laser-Assisted Grinding 3.7.2 Thermal Conduction for Laser Hearing 3.7.3 Laser-Assisted Grinding Trial 3.7.4 Results and Discussions 3.7.4.1 Groove Depth 3.7.4.2 Grinding Force 3.7.4.3 Surface Roughness and Microstructure of the Machined Surface 3.7.4.4 Subsurface Damage 3.7.5 Summary of the Laser-Assisted Process Development 3.8 Concluding Remarks References Chapter-4---Vibration-Assisted-Milling_2018_Hybrid-Machining 4 Vibration-Assisted Milling 4.1 Introduction 4.2 Principle of Vibration-Assisted Milling 4.2.1 Kinematics of Vibration-Assisted Milling 4.2.2 Types of TWS in Vibration-Assisted Milling 4.2.2.1 Type I TWS 4.2.2.2 Type II TWS 4.2.2.3 Type III TWS 4.2.3 Requirements of TWS 4.2.3.1 Type I Separation Requirements 4.2.3.1.1 Vibration in Cross-Feed Direction (CFVA Milling) 4.2.3.1.2 Vibration in Feed Direction (FVA Milling) 4.2.3.2 Type II Separation Requirements 4.2.3.2.1 Vibration in Cross-Feed Direction (CFVA Milling) 4.2.3.2.2 Vibration in Feed Direction (FVA Milling) 4.2.3.3 Type III Separation Requirements 4.2.3.3.1 Vibration in Cross-Feed Direction 4.2.3.3.2 Vibration in Feed Direction 4.3 Actuation Methods 4.3.1 Magneto-Strictive Actuator 4.3.2 Piezo-Actuator 4.3.2.1 Resonant Mode 4.3.2.2 Nonresonant Mode 4.3.3 Mechanical Actuation Methods 4.3.4 Summary of Actuation Methods 4.4 Case Study—Development of a Nonresonant VAMILL System and Machining Experiments 4.4.1 VAMILL System Development 4.4.2 Dynamic Analysis of the Vibration Stage 4.4.2.1 The Stiffness of the Double Four Connecting Rod Flexible Mechanism of the Outer Layer 4.4.2.2 Stiffness of the Single Rod Flexible Mechanism of Inner Ring 4.4.3 Control System Design and Vibration Test 4.4.4 Experiment Verification 4.5 Concluding Remarks References Further Reading Chapter-5---Electrochemical-Based-Hybrid-Machining_2018_Hybrid-Machining 5 Electrochemical Based Hybrid Machining 5.1 Introduction 5.2 Laser-Assisted Jet-Electrochemical Machining 5.3 Ultrasonic-Assisted Electrochemical Machining 5.4 Mechanical-Electrochemical Hybrid Processes 5.4.1 Mechano-Electrochemical Milling 5.4.2 Electrochemical Grinding 5.4.3 Orbital Electrochemical Abrading 5.4.4 Electrochemical Honing 5.4.5 Abrasive-Assisted Jet-Electrochemical Machining 5.5 Electrochemical Discharge Machining 5.6 Case Study: Mechano-Electrochemical Milling of Ti6Al4V 5.7 Concluding Remarks References Chapter-6---Electrochemical-Spark-Machining_2018_Hybrid-Machining 6 Electrochemical Spark Machining 6.1 Introduction 6.2 Comparison of the Related Processes 6.3 Analysis of ECSM Process 6.3.1 Reactions at the Cathode and Electrolyte Interface 6.3.2 Reaction at the Anode and Electrolyte Interface 6.3.3 Reduction in the Bulk Electrolyte 6.4 Electrochemical Spark Micromachining 6.5 Case Studies 6.5.1 Machining of Kevlar-Epoxy 6.5.2 Mechanism of Sparking and Analysis of ECSM 6.5.3 Machining of Alumina (Al2O3) and Quartz 6.5.4 Machining of Alumina and Glass Using Abrasive Cutting Tool 6.5.5 Some New Observations in ECSM of Quartz 6.5.6 Generation of Microchannels in Quartz 6.5.7 Fabrication of Microchannels on Silicon 6.5.7.1 Microchannels Machined With DC Power Supply 6.5.7.2 Microchannels Machined With HWR DC Power Supply 6.5.7.3 Microchannels Machined With AC Power Supply 6.5.7.4 Comparisons for Silicon Micromachining With DC, HWR DC, and AC Power Sources 6.6 Concluding Remarks References Chapter-7---Hybrid-Abrasive-Waterjet-and-Milling-Proces_2018_Hybrid-Machinin 7 Hybrid Abrasive Waterjet and Milling Process 7.1 Introduction and Motivation 7.2 Conventional Milling of Special Alloys 7.2.1 Deep Pocket Conventional Milling 7.3 Abrasive Waterjet Milling 7.3.1 Abrasive Waterjet Milling Solutions 7.3.1.1 Abrasive WaterJet Milling With Masks 7.3.1.2 Mask-less Abrasive Waterjet Milling 7.3.2 Geometrical Abrasive Waterjet Milling Strategies 7.3.3 AWJM Process Parameters 7.4 Hybrid Approach: Abrasive WaterJet Milling Roughing and Conventional Milling Finishing 7.4.1 Experimental Setup 7.4.2 Step 1: Abrasive Waterjet Milling Cycle 7.4.3 Step 2: Conventional Milling Cycle 7.5 Conclusions References Chapter-8---Hybrid-Machine-Tool-Design_2018_Hybrid-Machining 8 Hybrid Machine Tool Design 8.1 Introduction 8.2 State-of-the-Art Hybrid Machine Tools 8.2.1 Sequential Hybrid Machine Tools 8.2.1.1 EDM + Mechanical Machining Process Machine Tools 8.2.1.2 Additive Manufacturing Plus Milling 8.2.1.3 Laser Plus Milling Processes 8.2.2 Assisted Hybrid Machine Tools 8.2.3 Combined Hybrid Machine Tool 8.3 Design Principles of Hybrid Machine Tools 8.4 Case Study: Design of a Six-Axis Hybrid Micromachine Tool 8.4.1 Dynamic Design of Machine Structure 8.4.2 Motional Stages 8.4.3 Control System 8.4.4 Laser and Plugin Modules 8.4.5 Initial Machining Results 8.5 Concluding Remarks Reference Chapter-9---Material-Handling-System-for-a-Hybrid-Machi_2018_Hybrid-Machinin 9 Material Handling System for a Hybrid Machine 9.1 Introduction 9.2 System Specification 9.3 System Components 9.3.1 SCARA Manipulator 9.3.2 Robotiq Gripper 9.3.3 Vision System 9.3.4 Workpiece Fastening System 9.4 Process for Loading of the Machining Center 9.5 Measurement of Pose Accuracy 9.6 Material Handling System Integration Using a Terminal Control Protocol 9.6.1 Command Protocol 9.6.2 Data Flow 9.7 Summary and Future Work References Index_2018_Hybrid-Machining Index Backcover