Machining of Hard Materials

Hard machining is a recent technology that can be defined as a direct machining operation of workpieces that have hardness values typically in the 45-70HRc range using tools with geometrically-defined cutting edges. This operation always presents the challenge of selecting a cutting tool insert that facilitates an extended tool life and high-precision machining of the component. Hard machining presents several advantages when compared with the traditional methodology based on finish grinding operations after heat treatment of workpieces. This technology also offers a great contribution to sustainable manufacturing. Hard materials comprise hardened steels, high-speed steels, heat-treatable steels, tool steels, bearing steels and chilled/white cast irons. Inconnel, Hastelloy, cobalt alloys for biomedical applications and other special materials are also classified as hard materials. These materials are in constant use by the automotive industry for bearing production and for the machining of dies and moulds as well as other components for advanced industries. Machining of Hard Materials aims to provide the fundamentals and recent advances in the study of hard machining of materials. All chapters are written by international experts in this important field of research. Chapter 1 defines machining of hard materials and its application in industry. Chapter 2 is dedicated to advanced cutting tools used for the machining of hard materials. Chapter 3 describes the mechanics of the cutting and chip formation. Chapter 4 contains information on surface integrity. Chapter 5 is dedicated to finite element modelling and simulation. Finally, Chapter 6 is dedicated to computational methods and optimization. Machining of Hard Materials can serve as a useful reference for academics; manufacturing and materials researchers; manufacturing and mechanical engineers; and professionals in machining and related industries.