Erhan Budak, PhD – Professor, Faculty of Engineering and Natural Sciences, Sabanci University, Orhanli, Tuzla, Istanbul

Series: Manufacturing Technology Research; Mechanical Engineering Theory and Applications
BISAC: TEC020000; TEC046000; TEC009070
DOI: https://doi.org/10.52305/MWUU2566

Book Reviews

“This book offers a highly detailed and comprehensive exploration of milling, one of the most commonly used production methods in the manufacturing of complex parts across various industries. The subject matter presented is of vital importance to both industry and academia, addressing fundamental principles and modern advancements in milling technology. The broad spectrum of topics covered in this book gives a solid understanding of the essentials of milling from the fundamentals of kinematics, milling forces, and dynamics to advanced techniques aimed at addressing modern manufacturing challenges. It is also noteworthy that this content aligns with the objectives of Industry 4.0, with a focus on digitalization and the digital twin of process (mathematical modelling). As the industry moves towards greater automation and precision, this book serves as a valuable resource for both practitioners and academics.” – Professor Yusuf Z. Menceloglu, Faculty of Engineering and Natural Sciences, Sabanci University, Orta Mahalle, Türkiye

“A “closer look” of the book reveals that it is a state-of-the-art compilation by renowned experts from Europe, North America and Asia. It embraces modern milling machine design, simulation, the dynamics, as well as thermal analysis during machining operations. Cutting tools developments and tool wear are well covered. The chapters blend in the latest technologies and scientific tools in analysing the behavior of the milling process. It is a commendable effort by the editor in soliciting and putting the chapters together. Machine tools is regarded as the “mother” of all manufacturing processes, and indeed that any improvements will undoubtedly improve the quality of the offsprings. It is a highly readable text and is well recommended for the academia and industries in manufacturing.” – Andrew Y C Nee, Professor Emeritus, National University of Singapore

“In the field of machining science, Professor Erhan Budak is a well-known figure. His pioneering work on chatter in milling has earned him a distinguished reputation for addressing this complex and prevalent issue in the industry. For A Closer Look at Milling Machines and Processes, Budak has collaborated with several esteemed colleagues who each contributed chapters that highlight the current state of the art in machining technology. This book includes several chapters that focus on milling tools and wear, aiming to optimize process parameters. It delves into the mechanics and dynamics of turn-milling operations, which is particularly relevant for a range of applications, including turbine casings, crankshafts, and more. Notable contributions from experts like Tony Schmitz and Professor Bouzakis enrich these discussions. Additionally, the chapters on machining dynamics and chatter are led by Professor Budak himself, featuring insights from distinguished authors such as Professor Min Wan and Professor Zaeh. PhD students interested in the forefront of machining knowledge, as well as professional machinists eager to discover new ways to enhance productivity and quality, will greatly benefit from this book. It is impressive to note that Turkey has emerged as a powerhouse in machining science, largely due to the contributions of Professor Budak and other contributors within this book.” – Professor L.N. López de Lacalle, University of the Basque Country, Leioa, Spain

“This book is edited by Prof. E. Budak, a world-class expert in machine tool engineering. Each chapter is contributed by well-established academics and industrial experts in the field. The book begins with the fundamentals of the mechanics and dynamics of milling operations, followed by discussions on modeling machine tool structures, multi-axis feed drive control, and spindle dynamics. It covers process models including thin-walled machining, the design of special tools to avoid chatter, temperature effects, tool wear, and tool coating to enhance productivity. The book concludes with chapters on virtual machining-assisted milling process monitoring and turn-milling dynamics. It is an excellent resource for engineers who wish to understand the fundamental aspects of milling processes and machines.” – Professor Yusuf Altintas, Department of Mechanical Engineering, The University of British Columbia, Vancouver, Canada

Description

To produce the complex parts needed in many industries ranging from the aerospace and automotive industries to the medical field and to the energy sector, milling is either a key part of the manufacturing process or enables the tools for these industries to exist. Fundamentally, milling involves a cutting tool with multiple teeth that remove material in the form of chips on a milling machine having multiple axes. The milling processes have advanced significantly in terms of productivity and quality over time and naturally certain new issues have arisen. This book presents the current state of the art regarding these key issues while also proposing effective methodologies to optimize each part of this essential process.

The preliminary chapters focus on the fundamental kinematics, mechanics and dynamics of milling operations followed by design optimization and motion control of milling machines. Spindle dynamics strongly affecting the performance of milling machines is the topic of the following chapter.  The subsequent chapters focus on the milling of thin-walled parts, cutting tools with special geometries suppressing chatter vibrations and the thermal aspects of milling. Tool life has a direct effect on the productivity and cost of milling operations; thus, the next chapters are devoted to wear analysis and coatings for milling tools. Variations on the machine, tool and work conditions over time affect the performance in a milling operation. These changes can only be detected in real-time during operation using process monitoring which is the focus of the next chapter. In the last chapter, turn-milling offering higher productivity for large diameter parts and reduced tool wear in the machining of difficult-to-cut materials is presented as a growing technology of interest.