Volume is indexed by Thomson Reuters CPCI-S (WoS). The modelling of Machining Operations has become very widespread today, with many researchers developing models with which to predict metal-cutting performance. The aim here is to provide an answer to the challenges presented by the machining industry, which is presently facing very tight economical and environmental constraints. The collection of over 100 peer-reviewed papers covers twelve research topics, including: “Analytical and Numerical Modelling”; “Cutting Fundamentals: Input Parameters”; “Cutting Fundamentals: Experimental Validation”; “Surface Integrity”; “Surface Topography”; “Tool Wear and Tool Life”; “Dynamics and Stability”; “High-Speed Machining and 5-Axes Machining”; “Abrasive Machining”; “Ultra-Precision and Micromachining”; “Computer-Aided Manufacturing (CAM)”; “Experimental: Non-Conventional Machining”. This work will thus constitute an invaluable handbook on the subject.

Table of Contents:
Committees and Sponsors / Preface Chapter 1: Analytical and Numerical Modelling A Lagrangian FEM Model to Produce Saw-Toothed Macro-Chip and to Study the Depth of Cut Influence on its Formation in Orthogonal Cutting of Ti6Al4V 3D Modelling and Simulation of Gun Drilling Investigation of the Machining Behavior of Metal Matrix Composites (MMC) Using Chip Formation Simulation Computational Study of Ultrasonically-Assisted Turning of Ti Alloys Simulation of Multiple Chip Formation when Broaching SAE 5120 Low Alloy Steel 3D-FEM Modeling of Gear Skiving to Investigate Kinematics and Chip Formation Mechanisms Predictive Modeling for Distortion in Large, Thin-Walled Machined Components Modeling of Cutting Process with Cutter Axis Inclination Cutting Forces Modeling in Finish Turning of Inconel 718 Alloy with Round Inserts Real-Time Cutting Force Prediction and Cutting Force Coefficient Determination during Machining Processes An Analytical Thermomechanical Modelling of Peripheral Milling Process Using a Predictive Machining Theory Analytical Model of Chip Formation in Case of Orthogonal Cutting Processes CFRP Drilling Model: Fiber Orientation Influence on Mechanical Load and Delamination Numerical Model for Prediction of Cutting Force in Peripheral Milling Process Including Thrust and Tangential Damping FEM Based Design of a Chip Breaker for the Machining with PCD Tools 3D FEM Model for the Prediction of Chip Breakage A Numerical and Experimental Investigation of the Deformation Zones and the Corresponding Cutting Forces in Orthogonal Cutting On Methodologies inside Two Different Commercial Codes to Simulate the Cutting Operation Application of the Nodal Integrated Finite Element Method to Cutting: a Preliminary Comparison with the “Traditional” FEM Approach Validation of Finite Element Modeling of Drilling Processes with Solid Tooling in Metals Coating-Substrate-Simulation with an Advanced Adaptive Finite Element Code Virtual Reality Animation of Chip Formation during Turning Energy Efficient Process Planning Based on Numerical Simulations Simulation of the Temperature Distribution in NC-Milled Workpieces Numerical Prediction of the Interface Temperature Using Updated Finite Difference Approach Effect of Cutting Conditions on Temperature Generated in Drilling Process: a FEA Approach Analysis of Forces and Temperatures in Conventional and Ultrasonically-Assisted Cutting of Bone Chapter 2: Cutting Fundamentals: Input Parameters Input Data for the Numerical Simulation of Metal Cutting Inverse Flow Stress Calculation for Machining Processes Inverse Identification of Johnson-Cook Material Parameters from Machining Simulations New Thermal Issues on the Modelling of Tool-Workpiece Interaction: Application to Dry Cutting of AISI 1045 Steel Finite-Element Simulations of Split Hopkinson Test of Ti-Based Alloy The Numerical Investigation of Stress Distribution on the Rake Face for Grooved Cutting Tool Inserts Calibration of the Rheological Model Considering the Temperature in Milling Operation of Ti-6Al-4V: a Preliminary Analysis Chapter 3: Cutting Fundamentals: Experimental Validation Deformation and Microstructure in Machining Strain Rate Effect on the Mechanical Behavior of Austenitic Stainless Steel during Machining Technological and Environmental Aspects in Milling of ?-TiAl Evaluation of the Cutting Force and Geometric Error for Roughing Operation by Plunge Milling A Metal Cutting Approach to Investigate the Tribological Properties of Nano Crystalline Boric Acid and the Effect of its Carrying Medium Chapter 4: Surface Integrity Modeling the Process-Induced Modifications of the Microstructure of Work Piece Surface Zones in Cutting Processes Analytical and Numerical Modeling of Strain Hardening in AISI 304 Steel Cutting A Hybrid Approach to Predict Residual Stresses Induced by Ball-End Tool Finishing Milling of a Bainitic Steel Prediction of Machining Induced Surface Integrity Using Elastic-Viscoplastic Simulations and Temperature-Dependent Flow Softening Material Models in Titanium and Nickel-Based Alloys 3D Numerical Prediction of Residual Stresses in Turning of 15-5PH Prediction of Residual Stresses in Turning of Inconel 718 Residual Stress Prediction by Means of 3D FEM Simulation Analysis of Surface Integrity in Dry and Cryogenic Machining of AZ31B Mg Alloys Influence of Worn Tool on Polishability and Wear Resistance of VP20ISO Mold Steel High-Speed Milling Characteristics and the Residual Stresses Control Methods Analysis of Thin-Walled Parts Influence of Hard and Soft Inclusions on the Machinability and Polishability of VP100 Mold Steel Analysis of Surface Integrity for DIN 100Cr6 Steel Conical Bearing Rings after Hard Turning Surface Integrity Functional Analysis in Hard Turning AISI 8620 Case Hardened Steel through 3D Topographical Measurement Chapter 5: Surface Topography Modeling and Characterization of Surface Structures Produced by Milling Identification of Surface Generation Mechanisms Based on Process Feed-Back and Decomposition of Feed Marks Modulation-Assisted Machining: A New Paradigm in Material Removal Processes Chapter 6: Tool Wear and Tool Life Tool Load during Multi-Flank Chip Formation Development of a Simulation Model to Investigate Tool Wear in Ti-6Al-4V Alloy Machining Modeling and Optimization of Multiple Characteristics in the AISI 52100 Hardened Steel Turning Life Prediction of Cutting Tool by the Workpiece Cutting Condition An XPS Study of the Stratified Built-up Layers Developed onto the Tool Surface in the Dry Drilling of Ti Alloys Experimental Design Applied to the Machining of Windows Cage Ball Joints Homokinetic SAE 8620 Steel with CBN Tool Analysis of Sintering Parameters by SPS on Cemented Carbide Chapter 7: Dynamics and Stability Dynamic Study of Thin Wall Part Turning Stability Analysis of Machining with Spindle Speed Variation Investigating Dynamics of Machine Tool Spindles under Operational Conditions Fixed Boundaries Receptance Coupling Substructure Analysis for Tool Point Dynamics Prediction A Novel Approach to Thin-Wall Machining of Aerospace Structures - Stability Margin Prediction Using a New Damping Modelling Approach The Influence of Process Machine Interactions on the Stability of Parallel Milling Modeling the Varying Dynamics of Thin-Walled Aerospace Structures for Fixture Design Using Genetic Algorithms FEA-Methodology for the Prediction of Aluminium Thin Walled Part Deformation in Dry Milling Operations Modeling and Analysis Effects of Material Removal on Machining Dynamics in Milling of Thin-Walled Workpiece A New Experimental Setup and Method to Analyze Cutting Forces in Non-Stationary Conditions Chapter 8: High Speed Machining and 5 Axes Machining 5-Axis Flank Milling Tool Path Smoothing Based on Kinematical Behaviour Analysis Modeling Cutting Forces for Five Axis Milling of Sculptured Surfaces Mechanistic Model Based on the Actual Removal Volume during Simultaneous Five-Axis Milling Optimization of High Speed Machine Tool Frames Chapter 9: Abrasive Machining FEM-Based Simulation of Temperature in Speed Stroke Grinding with 3D Transient Moving Heat Sources Modeling and Simulation of Phase Transformation during Grinding Modeling of a Polishing Tool to Simulate Material Removal Finite Element Simulation of Quick – Stop Experiments for Better Understanding of Chip Formation in Grinding Optimization of Process Parameters in CFRP Machining with Diamond Abrasive Cutters Theoretical and Experimental Determination of Geometry Deviation in Continuous Path Controlled OD Grinding Processes Kinematic Model for Ultrasonic-Assisted Manufacturing of Bore Holes with Undefined Cutting Edges Machinability Evaluation in the Ultrasonic Drilling (USD) Process of Aluminum Oxide-based Ceramics FEM Simulation of Strain Rate in High Speed Grinding Evaluation of Quality of Steering Systems Using the Honing Process and Surface Response Methodology Study on the Simulation Model and High-Speed Characteristics of Cylindrical Grinding Chapter 10: Ultra-Precision and Micromachining Modelling of Ultra-Precision Turning Processes in Consideration of Unbalances Simulation Model for Micro-Milling Operations and Surface Generation Effects of the Cutting Tool Edge Radius on the Stability Lobes in Micro-Milling An Experimental Study on Dynamics and Stability of Miniature End Mills Investigation on Surface Finishing of Components Ground with Lapping Kinematics: Lapgrinding Process Chapter 11: Computer Aided Manufacturing (CAM) Interest of Multiphysics and Multilevel Simulation Approaches to Enhance the Machining Process Simulation of Serrated End Milling Using Solid Modeling Techniques Optimization of Non-Cutting Tool Paths Optimization of the 2 1/2 D Pocket Machining Using Multiple Tools Chapter 12: Experimental: Non Conventional Machining Surface Quality of Cavities Obtained by EDM Process Development of a Prototype of Electrochemical Machining Influence of Correlation between Electrical Discharge Machining Parameters with the Formation of Surface Defect’s in Products Machined by EDM Finite Element Modeling of Microstructural Changes in Hard Turning