Metal cutting, or simply machining, is one of the oldest processes for shaping components in the manufacturing industry.

It is estimated that 15% of the value of all mechanical components manufactured worldwide is derived from machining operations. However, despite its obvious economic and technical importance, machining remains one of the least understood manufacturing operations due to low predictive ability of the machining models. The old trial-and-error experimental method, originally developed in the middle of the 19th century is still in wide use in metal cutting research and development activities. Its modern form, known as the Unified or Generalized Mechanics Approach, has been pursued by Armarego and co-workers for years and then spread as the mechanistic approach in metal cutting. It was developed as an alternative to the metal cutting theory because the latter did not prove its ability to solve even simplest practical problems. Some researches even argued about advantages of experimental research over theoretical models. Although a number of books on metal cutting have been published, none of them provides critical comparison of different theories of metal cutting in their discussion of the corresponding models of chip formation which constitute the very core of the metal cutting

theory. After reading these books, a practical specialist in metal cutting does not feel to be sufficiently equipped with knowledge on the advantages and drawbacks of different models so he/she may wonder which particular model of chip formation to use in a given practical case. Besides, a great number of papers were published on the subject providing contradictive results and thus adding even more confusion to the matter. When one tries to learn the basics of the metal cutting theory, he/she takes a textbook on metal cutting (manufacturing, tool design, etc.) and then reads that the single-shear plane model of chip formation constitutes the very core of this theory. Although a number of other models are known to specialists in this field, the single-shear plane model survived all of them and, moreover, is still the first choice for studies on metal cutting, computer simulations programs and students textbooks. A simple explanation to this fact is that the model is easy to teach, to learn, and simple numerical examples to calculate cutting parameters can be worked out for student's assignments. Although it is usually mentioned that the model represents an idealized cutting process, no information about how far this idealization deviates from reality is provided. It is also interesting that this model was historically the first model developed, then was rejected, and then finally widely accepted remaining a paramount today. Still passive and for most part uncontrollable, the know theories of metal cutting are still in their developmental infancy. They cannot predict the major outcomes of the cutting process or to point out the direction of the process improvement. This book introduces a new physical concept in the science of metal cutting, a concepts that opens completely new avenues for improving the effectiveness and efficiency of the metal cutting process. Based on the system engineering concept in metal cutting proposed by the authors, the introduced approach provides a general methodology for treating all the physical and mechanical properties of the components of the cutting system, regardless of their nature and physical state. The authors show that this approach enables the prediction of the cutting process, improving its performance. They use this methodology to present and discuss a number of practical ways of solving real-world problems faced by researched, designers and by practitioners at the shop-floor level. Of enormous theoretical and practical significance, this groundbreaking work ushers in a new stage in science of metal cutting. It opens the door to systemic ways to design and optimize cutting process, cutting and machine tools. The proposed book provides an exceptional balance b etween general reading and research analysis, presenting industrial and academic requirements in terms of basic scientific factors as well as application potential. The authors distinguish his work from other works through these aspects:

Considering the cutting process as a system and utilizing the system properties for the optimization of this process. As such, the cutting process was defined as the purposeful

fracture of the layer being removed because the physical separation of this layer in the form of chips from the rest of the workpiece takes place.
Identifying the singularity of the cutting process among other closely related manufacturing processes by chip formation, caused by the combined effect of the bending and shear stresses in the deformation zone. Suggesting a distinctive way toward predictability of the metal cutting process through analyzing the energy flows in the cutting system. Devoting special attention to experimental methodology including extensive use of similarity theory in metal cutting. Solving a range of knowing problems in metal cutting including real-world practical problems faced by experienced practitioners at the shop-floor level.

The book is intended for a wide range of readers specializing of metal cutting, tool and machine tool design and application, and to all practicing engineers and metallurgists who are directly concerned with improving design and efficiency in the manufacturing industry. It is also very helpful for students because it covers the fundamental aspects of metal cutting showing their importance in solving realworld problems.

Table of Content Preface : Chapter 1. Chapter 2. Chapter 3. Chapter 4. Chapter 5. Chapter 6. Chapter 7. Chapter 8. Appendixes Machining Know How: What Seems to Be a Problem? Introduction: Metal Cutting Missed Chances or Science Without History Generalized Model of Chip Formation: Brittle, Ductile, Difficult-To-Machine Materials Materials Behavior in Metal Cutting: Cutting with Minimum Energy Spent Energy Flows in the Cutting System; Cutting System Efficiency Tribology of Metal Cutting: A Novel Physical Concept of the Tool Resource and Its Practical Applications Design of Experiments in Metal Cutting Tests: Theory Including GMDH, Methodology, Practical Examples Numerical Analyses of the Metal Cutting Process: MetCutSoft. Experimental Studies in Metal Cutting: Methodology and Applications