Chapter 1 Introduction 1.1 Typical steps from metal materials to components 1.1.1 Casting 1.1.2 3D printing 1.1.3 Metal forming 1.1.4 Machining processes 1.1.5 Abrasive-based machining and finishing operation 1.1.6 Desirable surface integrity 1.2 Associated phenomena in metal processing 1.2.1 Force and stress 1.2.2 Deformation rate and strain 1.2.3 Energy and heat generation 1.2.4 Temperature and material property alteration 1.2.5 Strain rate and efficiency 1.2.6 Friction, wear and lubrication References Chapter 2 Stress and Strain 2.1 Stress 2.1.1 Definition 2.1.2 Stress transformation 2.1.3 Principal stresses 2.1.4 Hydrostatic stress 2.1.5 Deviatoric stresses 2.1.6 Mohr's circle equations 2.1.7 Residual stress generated from metal processing 2.2 Strain 2.2.1 Engineering strain vs. true strain 2.2.2 Normal strain vs. shear strain 2.2.3 The strain tensor 2.2.4 Principal strain vs. volumetric strain 2.2.5 Isotropic elasticity 2.2.6 Strain energy 2.3 Strain rate 2.4 Other considerations in metal processing 2.4.1 Force and moment balances 2.4.2 Boundary conditions References Chapter 3 Strain hardening 3.1 Mechanism of strain hardening 3.2 Fundamentals of strain hardening 3.2.1 Tension test 3.2.2 Ductility 3.2.3 Elastic-plastic transition 3.2.4 Construction of stress-strain curves 3.2.5 Strain at necking 3.2.6 Stress behavior during necking 3.3 Strain hardening approximations 3.3.1 Power-law expression 3.3.2 Ludwik's equation 3.3.3 Linear strain hardening
3.3.4 Johnson-Cook constitutive model References Chapter 4 Material property dependence 4.1 Typical material property tests 4.1.1 The compression test 4.1.2 The torsion test 4.1.3 The bending test 4.1.4 The SHPB test 4.2 Typical factors influencing material property 4.2.1 Temperature 4.2.2 Strain rate 4.2.3 Hydrostatic pressure 4.2.4 Effect of grain size and grain boundary 4.2.5 Yield-point elongation 4.2.6 Anisotropy 4.3 Rate-dependent stress-strain properties References Chapter 5 Plasticity and plastic instability 5.1 Introduction 5.2 Yield criteria 5.2.1 Tresca yield criterion 5.2.2 Mises yield criterion 5.2.3 Other popular yield criteria 5.3 Plastic deformation modeling 5.3.1 Plastic work 5.3.2 Effective stress 5.3.3 Effective strain 5.3.4 Flow rules 5.3.5 Normality principle 5.3.6 Derivation of the von Mises effective strain 5.4 Application of Mises yield criterion 5.4.1 Uniaxial tension 5.4.2 Uniaxial compression 5.4.3 Balanced biaxial tension 5.4.4 Pure shear stress 5.4.5 Geometrical expression of yield criteria 5.5 Plastic instability analysis 5.5.1 Instability in uniaxial tension 5.5.2 Instability in balanced biaxial tension 5.5.3 Instability in pressurized thin-wall sphere 5.5.4 Significance of instability References Chapter 6 Hardness testing 6.1 Introduction 6.1.1 Fundamentals of indentation hardness testing 6.1.2 Development of indentation hardness testing 6.1.3 Indentation hardness testing practice 6.2 Macro-hardness indentation testing 6.2.1 The Brinell test 6.2.2 The Rockwell test
6.2.3 The Vickers hardness test 6.2.4 Hardness conversion 6.2.5 Correlation between hardness and tensile strength 6.3 Micro-hardness testing 6.3.1 The micro-Vickers test 6.3.2 The Knoop test 6.3.3 Microindentation hardness testing equipment 6.3.4 Specimen preparation 6.3.5 Important test considerations 6.4 Instrumented indentation testing 6.4.1 Testing equipment 6.4.2 Measurement of hardness and elastic modulus 6.4.3 Good experimental practice 6.4.4 Calibrations and future trends References Chapter 7 Limit analysis 7.1 Introduction 7.2 Lower bound analysis 7.2.1 Ideal work balance 7.2.2 Extrusion and deformation efficiency 7.2.3 Equal channel angular extrusion (ECAE) 7.2.4 Drawing and maximum drawing reduction 7.2.5 Effects of die angle and reduction 7.2.6 Swaging 7.3 Upper bound analysis 7.3.1 Energy dissipation on plane of shear 7.3.2 Plane-strain frictionless extrusion 7.3.3 Plane-strain frictionless indentation 7.3.4 Plane-strain compression 7.3.5 Another approach to upper bound analysis 7.3.6 Typical combined upper-bound analysis 7.3.7 Axisymmetric drawing References Chapter 8 Slab analysis 8.1 Friction and lubrication 8.1.1 Friction effects in metal forming 8.1.2 Thick-film lubrication 8.1.3 Thin-film lubrication 8.1.4 Mixed lubrication 8.1.5 Boundary lubrication 8.2 Friction models 8.2.1 The Coulomb friction model 8.2.2 The Tresca friction model 8.3 Slab analysis application 8.3.1 Slab analysis procedure 8.3.2 Wire and rod drawing 8.3.3 Flat rolling 8.3.4 Axially symmetric compression 8.4 Estimation of the effect of friction 8.4.1 Friction in plane-strain compression
8.4.2 Sticking friction 8.4.3 Mixed sticking-sliding conditions 8.4.4 Constant shear stress interface 8.4.5 Sand-pile analogy 8.4.6 Roll flattening effect 8.4.7 Roll bending effect References Chapter 9 Machining mechanics and analytical modeling 9.1 Mechanics of metal cutting and chip formation 9.1.1 Orthogonal cutting model 9.1.2 Cutting ratio 9.1.3 Shear strain and strain rate 9.1.4 Velocity in the cutting zone 9.1.5 Chip morphology 9.2 Cutting forces and power 9.2.1 Traditional analysis of cutting forces 9.2.2 Friction coefficient 9.2.3 Power and specific energy 9.3 Cutting temperature 9.3.1 Heat and mean temperature 9.3.2 Temperature distribution 9.3.3 Temperature in high-speed machining 9.4 Ultraprecision machining 9.4.1 Tool edge radius effect 9.4.2 Specific cutting force and energy 9.4.3 Minimum uncut chip thickness 9.4.4 Ductile-model machining 9.4.5 Extrusion-like chip formation References Chapter 10 Finite element method and analysis 10.1 Principle of finite element method 10.1.1 Discretization 10.1.2 Strain and stress calculation by FEM 10.1.3 Time integration in non-linear and dynamic FEM analysis 10.1.4 Commercial FEM program for metal processing 10.2 FEM analysis framework in metal forming 10.2.1 FEM modeling approach 10.2.2 Performing the FEM analysis 10.2.3 Axisymmetric vs. plane strain 2D model 10.2.4 Isothermal vs. thermally coupled FEM models 10.2.5 Material behavior 10.2.6 Material models 10.2.7 Friction models 10.2.8 Obtaining postprocessing results 10.3 FEA of plane strain compression 10.3.1 The plane strain compression test 10.3.2 Experimental investigation 10.3.3 FEM model and input data to the model 10.3.4 Similarity between simulation and experiment 10.3.5 Information deduced from the simulation models
10.3.6 Concluding remarks 10.4 FEA machining of titanium alloys and microstructure evolution 10.4.1 Introduction of Ti-6Al-4V alloys 10.4.2 FE modeling including boundary conditions 10.4.3 Constitutive model for machining of Ti-6Al-4V alloys 10.4.4 Incremental model for stress-strain induced microstructure evolution 10.4.5 Workpiece material property 10.4.6 Orthogonal machining experiment 10.4.7 Validation of constitutive model parameters 10.4.8 Validation of microstructure evolution model parameters 10.4.9 Summary remark References Chapter 11 Abrasive-based material removal process 11.1 Fundamentals of grinding 11.1.1 Grinding wheel 11.1.2 The behavior of single abrasive during grinding 11.1.3 Distribution of force and energy in the grinding process 11.1.4 Grinding mechanism 11.1.5 Grit and bond wear 11.2 The mechanics of the grinding process 11.2.1 Material removal and material removal rate 11.2.2 Wear and G ratio 11.2.3 Cutting path and contact length 11.2.4 Undeformed chip thickness and chip cross-sectional area 11.2.5 Grinding force and power and energy 11.3 Heat generation and temperature distribution in grinding 11.4 The honing of engine cylinder bore 11.4.1 Kinematic analysis of honing process 11.4.2 Abrasives distribution model in honing stone 11.4.3 Discrete model of engine cylinder bore 11.4.4 Feeding model based on the force matching method 11.4.5 Simulation process 11.4.6 Simulated honed cylinder bore with an initial regular cylindrical shape 11.4.7 Simulated honed cylinder bore by considering its previous shape deviation 11.4.8 Summary remarks References Chapter 12 Machined surface integrity and its functional performance 12.1 Surface integrity definition and fundamentals 12.1.1 Surface roughness 12.1.2 Micro-hardness 12.1.3 Residual stress 12.1.4 Microstructural alteration 12.1.5 Machined surface generation mechanisms 12.2 Mechanical effects upon surface integrity 12.2.1 Plastic deformation 12.2.2 Mechanically induced grain refinement 12.2.3 Work hardening 12.2.4 Geometrical defects 12.3 The Impact of surface integrity on anti-fatigue performance 12.3.1 Considering fatigue behavior based on manufacturing perspective
12.3.2 Material subtraction and fatigue behavior 12.3.3 Anti-fatigue performance after mechanical machining 12.4 Anti-fatigue oriented approaches for metal processing design 12.4.1 Forward modeling from metal processing to fatigue or wear behavior 12.4.2 Backward modeling method based on service condition 12.4.3 Interactive approach incorporated with service condition References
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