Provides a comprehensive description for machining technologies of stainless steels and super alloys with consideration to current industrial applications.
* Presents current and recent developments related to traditional and nontraditional machining techniques of stainless steels and super alloys
* Arranges types of stainless steels and super alloys in qualitative and quantitative form, as related to their machining characteristics, providing the reader with information regarding optimum working condition for each material
* Proposes a 10-level machinability chart to rank important grades of stainless steels
* Arranges the machinability rating of the most commonly used super alloys in a descending order
* Presents non-traditional machining processes along with some hybrid processes which have been applied successfully to stainless steels and super alloys
Autorentext
Professor Helmi A. Youssef, born in August, 1938 in Alexandria, Egypt, has acquired his B.Sc. in Production Engineering, Alexandria University in 1960. He completed then his scientific building in Carolo-Welhelmina, TH Braunschweig in Germany, during the period 1961-1967, where he acquired his Dipl.-Ing., and Dr.-Ing. Degree in the domain of Non-traditional Machining. In Alexandria University, he has been promoted to associate, then since 1978 to full professor. In the period 1995-1998, professor Youssef was the chairman of the Production Engineering Dept., and since 1989, he was a member of the scientific committee for promotion of professors in Egyptian Universities. Between 1975 and 1998, he was a visiting professor in many Arab, and German Universities. He established his own laboratories, and supervised many M.Sc. and Ph D theses. Professor Youssef has organized and participated in international conferences. He has published many scientific papers in specialized journals, and authored books in his fields of specialization; two of which have been published by CRC, on machining and manufacturing technologies, in 2008, and 2011, respectively. Currently, Prof. Youssef is Emeritus Professor in PED, Alexandria University.
Inhalt
Preface xiii
About the Author xix
Acknowledgments xxi
Nomenclature xxiii
Glossary xxvii
1 Introduction 1
1.1 Stainless Steels and Super Alloys as DifficulttoCut Materials 1
1.1.1 Historical Background of Stainless Steels and Super Alloys 2
1.1.1.1 Stainless Steels 2
1.1.1.2 Super Alloys 3
1.1.2 Industrial Applications of Stainless Steels and Super Alloys 3
1.1.2.1 Stainless Steels 3
1.1.2.2 Super Alloys 4
1.2 Traditional and Nontraditional Machining Processes 4
1.2.1 Importance of Machining in Manufacturing Technology 4
1.2.2 Classification of Machining Processes 6
1.2.3 Variables of Machining Processes 9
1.2.3.1 Input (Independent) Variables 9
1.2.3.2 Output (Dependent) Variables 9
References 10
2 Types and Classifications of Stainless Steels 11
2.1 Role of Alloying Elements in Stainless Steels 11
2.2 Types of Stainless Steels 13
2.2.1 Basic Alloys of Stainless Steels (Ferritic, Martensitic, Austenitic) 13
2.2.1.1 Ferritic Stainless Steels of AISIDesignations 13
2.2.1.2 Martensitic Stainless Steels also of AISIDesignation 18
2.2.1.3 Austenitic Stainless Steels of AISIDesignation 19
2.2.2 Derived Alloys of Stainless Steels (Duplex, PHAlloys) 22
2.3 Concluding Comments and Comparative Characteristics 23
References 26
3 Types and Classifications of Super Alloys 27
3.1 General Features and Classifications 27
3.2 Types of Super Alloys 28
3.2.1 FeBase Alloys 31
3.2.2 NiBase Alloys 34
3.2.3 CoBase Alloys 39
References 41
4 Traditional Machining Machinability, Tooling, and Cutting Fluids 43
4.1 Machinability Concept in Metal Cutting 43
4.1.1 Definition and General Aspects 43
4.1.2 Quantifying and Criteria of Machinability 44
4.1.2.1 Tool Life Criterion 46
4.1.2.2 Cutting Forces and Power Consumption Criterion 48
4.1.2.3 Surface Finish Criterion 50
4.1.3 Enhancing Machinability of DifficulttoCut Materials 50
4.1.3.1 Adoption of Free Machining Steels and Alloys 50
4.1.3.2 Thermally Assisted Machining (Hot Machining) 52
4.1.3.3 High Speed Machining 52
4.1.3.4 UltrasonicAssisted Machining 60
4.1.3.5 Advanced Cooling Techniques 61
4.1.3.6 Cryogenic Treatment of Tool Materials 63
4.2 Cutting Tool Materials 63
4.2.1 Characteristics of an Ideal Tool Material 64
4.2.2 Types of Cutting Tool Materials 65
4.2.2.1 High Speed Steel (HSS) 65
4.2.2.2 Cast Nonferrous Alloys (Stellite and UCON) 67
4.2.2.3 Cemented Carbides (Widia) 69
4.2.2.4 Cemented Titanium Carbides (TiCBased Tools) 73
4.2.2.5 Cermets 73
4.2.2.6 Ceramics (AluminaBased Tools) 73
4.2.2.7 SiAlON 74
4.2.2.8 Cubic Boron Nitride (CBN) 74
4.2.2.9 Diamond 75
4.2.3 Tool Materials for Machining of Stainless Steels and Super Alloys 75
4.2.3.1 Cutting Tool Materials for Stainless Steels 76
4.2.3.2 Tool Materials for Super Alloys 77
4.3 Cutting Fluids for Stainless Steels and Super Alloys 81
4.3.1 Functions, Characteristics, and General Considerations 81
4.3.2 Types of Cutting Fluids 82
4.3.2.1 WaterBase Liquids 82
4.3.2.2 Neat Oils 83
4.3.2.3 Liquid Gas or Cryogenic Coolants 83
4.3.2.4 Solid Lubricants 84
4.3.3 Application Methods 84
4.3.4 Cutting Fluids for Stainless Steels 85
4.3.4.1 Sulfochlorinated Cutting Oils 85
4.3.4.2 Emulsifiable Fluids 86
4.3.4.3 Selection of Cutting Fluid for Stainless Steels 87
4.3.5 Cutting Fluids for Super Alloys 88
4.3.5.1 Turning, Planing, Shaping, and Boring 88
4.3.5.2 Broaching 88
4.3.5.3 Drilling and Reaming 89