This book provides essential information on metal forming, utilizing a practical distinction between bulk and sheet metal forming. In the field of bulk forming, it examines processes of cold, warm and hot bulk forming, as well as rolling and a new addition, the process of thixoforming. As for the field of sheet metal working, on the one hand it deals with sheet metal forming processes (deep drawing, flange forming, stretch drawing, metal spinning and bending). In terms of special processes, the chapters on internal high-pressure forming and high rate forming have been revised and refined. On the other, the book elucidates and presents the state of the art in sheet metal separation processes (shearing and fineblanking). Furthermore, joining by forming has been added to the new edition as a new chapter describing mechanical methods for joining sheet metals.
The new chapter Basic Principles addresses both sheet metal and bulk forming, in addition to metal physics, plastomechanics and computational basics; these points are complemented by the newly added topics of metallography and analysis, materials and processes for testing, and tribology and lubrication techniques. The chapters are supplemented by an in-depth description of modern numeric methods such as the finite element method. All chapters have been updated and revised for the new edition, and many practical examples from modern manufacturing processes have been added.

The book series on manufacturing processes for engineers is a reference work for scientific and industrial experts. This volume on Turning, Milling and Drilling starts from the basic principles of machining with geometrically defined cutting edges based on a common active principle. In addition, appropriate tool designs as well as the reasonable use of cutting material are presented. A detailed chapter about the machinability of the most important workpiece materials, such as steel and cast iron, light metal alloys and high temperature resistant materials imparts a broad knowledge of the interrelations between workpiece materials, cutting materials and process parameters.

This book is in the RWTHedition Series as are the other four volumes of the reference work.

The future of manufacturing companies depends largely on their ability to adapt to swiftly changing global conditions. These are exemplified by international com- tition, rapidly growing intercommunication and the increased significance of en- ronmental issues [KLOC98a, ENGE02]. Precision machining with geometrically undefined cutting edges represents a key production engineering technology with high efficiency, security and machining quality. DIN norm 8589 subsumes within the group "machining with geometrically - defined cutting edges" the following material removal manufacturing processes: grinding, honing, lapping, free abrasive grinding and abrasive blast cutting. - chining is carried out in these production methods by means of more or less - regularly formed grains composed of hard substances brought into contact with the material. Of all methods understood as machining with geometrically undefined cutting edges, only grinding, honing and lapping can, strictly speaking, be considered p- cision machining. Free abrasive grinding and abrasive blast cutting, also treated in this book, represent a special group, as they generally cannot bring about geom- rical change in the material.

This book provides essential information on metal forming, utilizing a practical distinction between bulk and sheet metal forming. In the field of bulk forming, it examines processes of cold, warm and hot bulk forming, as well as rolling and a new addition, the process of thixoforming. As for the field of sheet metal working, on the one hand it deals with sheet metal forming processes (deep drawing, flange forming, stretch drawing, metal spinning and bending). In terms of special processes, the chapters on internal high-pressure forming and high rate forming have been revised and refined. On the other, the book elucidates and presents the state of the art in sheet metal separation processes (shearing and fineblanking). Furthermore, joining by forming has been added to the new edition as a new chapter describing mechanical methods for joining sheet metals. The new chapter "Basic Principles" addresses both sheet metal and bulk forming, in addition to metal physics, plastomechanics and computational basics; these points are complemented by the newly added topics of metallography and analysis, materials and processes for testing, and tribology and lubrication techniques. The chapters are supplemented by an in-depth description of modern numeric methods such as the finite element method. All chapters have been updated and revised for the new edition, and many practical examples from modern manufacturing processes have been added.

The book series on manufacturing processes for engineers is a reference work for scientific and industrial experts. This volume on Turning, Milling and Drilling starts from the basic principles of machining with geometrically defined cutting edges based on a common active principle. In addition, appropriate tool designs as well as the reasonable use of cutting material are presented. A detailed chapter about the machinability of the most important workpiece materials, such as steel and cast iron, light metal alloys and high temperature resistant materials imparts a broad knowledge of the interrelations between workpiece materials, cutting materials and process parameters.

This book is in the RWTHedition Series as are the other four volumes of the reference work.

1 Zielsetzung im Werkzeugbau.- 1.1 Zielkonflikte im Werkzeugbau.- 1.2 Kundennutzen.- 1.3 OEkonomischer Nutzen.- 2 Strategische Ausrichtung des Werkzeugbaus.- 2.1 Konzentration auf Kernerzeugnisse und Kernprozesse.- 2.1.1 Ermittlung von Auftragsarten und Erzeugnisspektrum.- 2.1.1.1 Auftragsarten.- 2.1.1.2 Erzeugnisspektrum.- 2.1.2 Identifikation von Kernerzeugnissen.- 2.1.2.1 Ermittlung der Know-how Relevanz.- 2.1.2.2 Ermittlung des Zulieferpotentials.- 2.1.3 Bestimmung der Kernprozesse.- 2.1.3.1 Erfassung der Prozesse im Werkzeugbau.- 2.1.3.2 Bewertung von Prozess-Know-how und Zulieferpotential.- 2.1.3.3 Ermittlung des Kundennutzens.- 2.1.3.4 Durchfuhrung eines Leistungsvergleichs.- 2.1.3.5 Identifikation von Kernprozessen.- 2.2 Prozessorientierte Organisationsgestaltung.- 2.2.1 Prozessorientierung - ein ganzheitlicher Ansatz.- 2.2.2 Prozessorientierte Ablaufgestaltung.- 2.2.2.1 Prozessanalyse.- 2.2.2.2 Ermittlung von Schwachstellen.- 2.2.2.3 Ableitung von Massnahmen.- 2.2.2.4 Umsetzung.- 2.2.3 Prozessorientierte Gestaltung der Aufbauorganisation.- 2.2.3.1 Gestaltungsparameter und Auswahlgroessen.- 2.2.3.2 Interne Organisationsformen.- 2.2.3.3 Werkzeugbau als Profit-Center.- 2.3 Dimensionierung von Kapazitaten.- 2.3.1 Marktprognosen.- 2.3.1.1 Methodeneinsatz.- 2.3.1.2 Sicherheit der Prognose.- 2.3.2 Prognose fur einzelne Auftragstypen.- 2.3.3 Kapazitatsdimensionierung.- 2.4 Schnittstellenfunktion des Werkzeugbaus.- 2.4.1 Position des Werkzeugbaus in der Gesamtprozesskette.- 2.4.1.1 Schnittstellen der Hauptprozesse.- 2.4.1.2 Schnittstellendefinition anhand der Auftragsarten.- 2.4.2 Integrationskriterien fur den Werkzeugbau.- 2.4.3 Integrationsalternativen.- 3 Standardisierung im Werkzeugbau.- 3.1 Produktstrukturierung im Werkzeugbau.- 3.1.1 Ziele der Betriebsmittelstrukturierung.- 3.1.2 Schwachstellen bei der Produktstrukturierung im Werkzeugbau.- 3.1.3 Vorgehensweise bei der Produktstrukturierung.- 3.2 Nummernsysteme.- 3.2.1 Ziele der Einfuhrung von Nummernsystemen.- 3.2.2 Vergleich verschiedener Nummernsysteme.- 3.2.3 Grundlagen der Klassifizierung.- 3.2.4 Vorgehensweise zur Festlegung neuer Nummernsysteme.- 3.3 Sachmerkmal-Leisten.- 3.3.1 Bedeutung von Sachmerkmalen.- 3.3.2 Vorgehensweise zur Erstellung von Sachmerkmal-Leisten.- 4 Leistungsfahige Fertigungstechnologien.- 4.1 Produktspektrum im Werkzeug- und Formenbau.- 4.2 Muster und Prototypen.- 4.2.1 Prototypenbedarf in der Produktentwicklung.- 4.2.2 Rapid Prototyping-Verfahren zur Modell- und Musterteilherstellung.- 4.2.2.1 Charakteristika und Potentiale des Rapid Prototyping.- 4.2.2.2 Industriell eingesetzte Verfahren.- 4.2.2.3 Entwicklungstendenzen.- 4.2.3 Rapid Prototyping-Prozessketten zur Prototyp- und Kleinserienfertigung.- 4.2.3.1 Herstellung von Kunststoff-Prototypen und -Kleinserien.- 4.2.3.2 Giess- und Abformprozesse zur Herstellung metallischer Bauteile.- 4.2.4 Rapid Tooling-Verfahren zur Werkzeug- und Formenherstellung.- 4.2.5 Verfahrensauswahl.- 4.3 Spritz- und Druckgiessformen.- 4.3.1 Schruppfrasen.- 4.3.1.1 Werkzeuge und Schneidstoffe.- 4.3.1.2 Prozessauslegung und Bearbeitungsstrategien.- 4.3.2 Schlichtfrasen.- 4.3.2.1 Frasbearbeitung filigraner Geometrien mit schlanken Schaftfrasern.- 4.3.2.2 Hochgeschwindigkeitsfrasen von Graphit- und Kupferelektroden.- 4.3.3 Funkenerosive Senkbearbeitung.- 4.3.4 Fertigung filigraner Elektroden mittels Ultraschallschwinglappen.- 4.3.4.1 Technologische Grundlagen.- 4.3.4.2 Anwendungsbeispiel.- 4.4 Schmiedegesenke.- 4.4.1 Hartfrasen.- 4.4.1.1 Werkzeuge und Schneidstoffe.- 4.4.1.2 Prozessauslegung und Bearbeitungsstrategien.- 4.4.1.3 Integration von Frasstrategien in CAM-Systeme.- 4.4.2 Funkenerosive Senkbearbeitung.- 4.4.3 Standzeiterhoehung durch Laseroberflachenbehandlung.- 4.4.3.1 Verfahrensgrundlagen und -varianten.- 4.4.3.2 Anlagen zur Oberflachenbehandlung.- 4.4.3.3 Anwendungsbeispiele und Einsatzergebnisse.- 4.4.3.4 Arbeitsschutzmassnahmen.- 4.5 Zieh- und Presswerkzeuge.- 4.5.1 Verfahrensalternative

The future of manufacturing companies depends largely on their ability to adapt to swiftly changing global conditions. These are exemplified by international com- tition, rapidly growing intercommunication and the increased significance of en- ronmental issues [KLOC98a, ENGE02]. Precision machining with geometrically undefined cutting edges represents a key production engineering technology with high efficiency, security and machining quality. DIN norm 8589 subsumes within the group "machining with geometrically - defined cutting edges" the following material removal manufacturing processes: grinding, honing, lapping, free abrasive grinding and abrasive blast cutting. - chining is carried out in these production methods by means of more or less - regularly formed grains composed of hard substances brought into contact with the material. Of all methods understood as machining with geometrically undefined cutting edges, only grinding, honing and lapping can, strictly speaking, be considered p- cision machining. Free abrasive grinding and abrasive blast cutting, also treated in this book, represent a special group, as they generally cannot bring about geom- rical change in the material.