Fundamentals of machining processes: conventional and nonconventional processes

Cover......Page 1
Half Title......Page 2
Title Page......Page 4
Copyright Page......Page 5
Dedication......Page 6
Contents......Page 8
Preface......Page 20
Foreword......Page 24
Acknowledgments......Page 26
Abbreviations......Page 28
List of Symbols......Page 32
Greek Symbols......Page 41
Author......Page 46
 1.1 Introduction......Page 48
 1.2 Historical Background......Page 49
 1.3 Classification of Machining Processes......Page 50
   1.3.1.1 Form Cutting......Page 51
   1.3.1.3 Form and Generation Cutting......Page 52
  1.3.2 Machining by Abrasion......Page 53
  1.3.3 Machining by Erosion......Page 56
  1.3.4 Hybrid Machining......Page 57
  1.3.5 Micromachining......Page 58
  1.3.6 Assisted Machining Processes......Page 59
 1.5 Variables of Machining Processes......Page 60
 1.6 Machining Process Selection......Page 61
 1.7 Review Questions......Page 62
 2.1 Introduction......Page 64
 2.2 Geometry of Single-Point Tools......Page 67
  2.2.2 Tool Angles in Orthogonal System of Planes......Page 68
  2.2.3 Relationship between the ASA and Orthogonal Systems......Page 72
  2.2.4 Effect of Tool Setting......Page 73
  2.2.5 Effect of Tool Feed Motion......Page 74
  2.2.6 Solved Example......Page 75
  2.3.1 Twist Drills......Page 76
  2.3.2 Reamers......Page 78
  2.3.3 Broach Tools......Page 79
  2.3.4 End Mills......Page 80
  2.3.5 Plain Milling Cutters......Page 81
  2.4.1 Requirements of Tool Materials......Page 82
   2.4.2.1 Ferrous Tool Materials......Page 83
   2.4.2.2 Nonferrous Tool Materials......Page 87
   2.4.2.3 Nanocoated Tools......Page 93
 2.5 Problems......Page 96
 2.6 Review Questions......Page 97
  3.2.1 Discontinuous Chip......Page 100
  3.2.2 Continuous Chip......Page 102
 3.3 Orthogonal Cutting......Page 104
  3.3.1 Force Diagram......Page 106
  3.3.2 Shear Angle......Page 108
  3.3.4 Velocity Relations......Page 110
  3.3.5 Shear Strain......Page 111
  3.3.7 Theory of Ernst and Merchant......Page 112
  3.3.8 Theory of Lee and Shaffer......Page 114
  3.3.10 Energy Consideration......Page 115
  3.3.11 Solved Example......Page 116
 3.4 Heat Generation in Metal Cutting......Page 117
  3.4.1 Cutting Tool Temperature......Page 120
  3.4.2 Temperature at Shear Plane......Page 121
  3.4.3 Factors Affecting the Tool Temperature......Page 122
   3.4.3.3 Cutting Fluids......Page 123
   3.4.3.4 Minimum Quantity Lubrication......Page 128
  3.4.4 Solved Example......Page 129
 3.5 Problems......Page 131
 3.6 Review Questions......Page 134
  4.1.2 Forms of Tool Wear......Page 136
   4.1.2.1 Crater Wear......Page 138
   4.1.2.2 Flank Wear......Page 139
 4.2 Tool Life......Page 141
  4.2.1 Formulation of Tool-life Equation......Page 142
  4.2.2 Criteria for Judging the End of Tool Life......Page 143
   4.2.3.1 Cutting Conditions......Page 144
   4.2.3.4 Tool Material......Page 145
   4.2.3.7 Coolant......Page 146
  4.2.4 Solved Example......Page 147
  4.3.1 Cutting Speed for Minimum Cost......Page 148
  4.3.2 Cutting Speed for Minimum Time......Page 152
  4.3.3 Cutting Speed for Maximum Profit Rate......Page 154
  4.3.4 Solved Example......Page 156
 4.4 Problems......Page 157
 4.5 Review Questions......Page 158
 5.2 Turning......Page 160
  5.2.1 Cutting Tools......Page 161
  5.2.2 Cutting Speed, Feed, and Machining Time......Page 162
  5.2.3 Elements of Undeformed Chip......Page 163
  5.2.4 Cutting Forces, Power, and Removal Rate......Page 164
   5.2.5.1 Factors Related to Tool......Page 166
   5.2.5.3 Factors Related to Cutting Conditions......Page 168
  5.2.6 Surface Finish......Page 169
  5.2.8 Solved Example......Page 171
  5.3.1 Drill Tool......Page 174
  5.3.2 Elements of Undeformed Chip......Page 176
  5.3.3 Cutting Forces, Torque, and Power......Page 179
   5.3.4.2 Factors Related to the Drill Geometry......Page 182
  5.3.5 Drilling Time......Page 183
  5.3.6 Dimensional Accuracy......Page 184
  5.3.9 Solved Example......Page 186
 5.4 Reaming......Page 189
  5.4.1 Finish Reamers......Page 191
  5.4.2 Elements of Undeformed Chip......Page 192
  5.4.3 Forces, Torque, and Power in Reaming......Page 193
  5.4.4 Reaming Time......Page 194
  5.4.5 Selection of the Reamer Diameter......Page 195
  5.4.6 Selection of Reaming Conditions......Page 196
  5.4.7 Solved Example......Page 198
  5.5.1 Turning......Page 199
  5.5.2 Drilling......Page 201
 5.6 Review Questions......Page 203
  6.2.2 Elements of Undeformed Chip......Page 206
  6.2.3 Cutting Forces, Power, and Removal Rate......Page 210
  6.2.4 Shaping Time......Page 211
  6.2.6 Solved Example......Page 212
  6.3.1 Horizontal (Plain) Milling......Page 215
   6.3.1.2 Cutting Speed of Tool and Workpiece Feed......Page 219
   6.3.1.3 Elements of Undeformed Chip......Page 220
   6.3.1.4 Forces and Power in Milling......Page 221
   6.3.1.5 Surface Roughness in Plain Milling......Page 225
   6.3.1.6 Milling Time......Page 226
   6.3.1.7 Factors Affecting the Cutting Forces......Page 227
  6.3.2 Face Milling......Page 228
   6.3.2.1 Face-Milling Cutters......Page 229
   6.3.2.2 Elements of Undeformed Chip......Page 230
   6.3.2.3 Surface Roughness......Page 233
   6.3.2.5 Solved Example......Page 235
  6.3.3 Selection of Milling Conditions......Page 236
 6.4 Broaching......Page 237
  6.4.1 Broach Tool......Page 241
  6.4.2 Chip Formation in Broaching......Page 245
  6.4.3 Broaching Force and Power......Page 246
  6.4.4 Broaching Time......Page 247
  6.4.5 Accuracy and Surface Finish......Page 248
  6.4.6 Broach Devsign......Page 249
  6.4.7 Solved Example......Page 251
  6.5.1 Shaping......Page 252
  6.5.2 Horizontal Milling......Page 253
  6.5.3 Vertical Milling......Page 254
  6.5.4 Broaching......Page 255
 6.6 Review Questions......Page 256
 7.2 History of HSM......Page 258
 7.3 Chip Formation in HSM......Page 259
 7.4 Characteristics of HSM......Page 260
  7.5.1 Force Measurement......Page 264
   7.5.1.2 Dynamometers Based on Strain Measurement......Page 265
  7.5.2 Vibration Measurements......Page 266
   7.5.3.1 Thermocouple Techniques......Page 267
   7.5.3.2 Infrared Techniques......Page 269
 7.6 Applications of HSM......Page 270
 7.7 Advantages of HSM......Page 272
 7.9 Review Questions......Page 273
 8.1 Introduction......Page 274
   8.2.1.1 Abrasive Materials......Page 277
   8.2.1.3 Wheel Bond......Page 279
   8.2.1.5 Wheel Structure......Page 280
   8.2.1.6 Grinding-Wheel Designation......Page 281
   8.2.1.8 Selection of Grinding Wheels......Page 282
   8.2.1.10 Truing and Dressing......Page 285
  8.2.2 Wheel Wear......Page 287
  8.2.3 Economics of Grinding......Page 289
  8.3.1 Elements of Undeformed Chip......Page 291
  8.3.2 Grinding Forces, Power, and Removal Rate......Page 294
  8.3.4 Grinding Time......Page 295
  8.3.5 Solved Example......Page 297
   8.3.6.1 Plain (Periphery) and Face Grinding with Reciprocating Feed......Page 298
   8.3.6.3 Creep-Feed Grinding......Page 299
  8.4.1 Elements of Undeformed Chip......Page 300
  8.4.2 Forces, Power, and Removal Rate......Page 302
  8.4.4 Factors Affecting Surface Roughness......Page 303
  8.4.5 Solved Example......Page 305
   8.4.6.1 External Cylindrical Grinding......Page 307
   8.4.6.2 External Centerless Grinding......Page 310
   8.4.6.3 Internal Cylindrical Grinding......Page 312
   8.4.6.4 Internal Centerless Grinding......Page 313
 8.6 Problems......Page 315
 8.7 Review Questions......Page 317
 9.2 Honing......Page 320
  9.2.1 Honing Kinematics......Page 323
  9.2.2 Process Components......Page 325
  9.2.3 Process Description......Page 326
  9.2.4 Process Characteristics......Page 327
 9.3 Lapping......Page 330
  9.3.1 Process Components......Page 332
  9.3.2 Mechanics of Lapping......Page 335
  9.3.3 Process Characteristics......Page 337
  9.3.4 Lapping Operations......Page 340
 9.4 Superfinishing......Page 341
  9.4.1 Kinematics of Superfinishing......Page 345
  9.4.2 Process Characteristics......Page 347
 9.6 Buffing......Page 349
 9.7 Review Questions......Page 350
 10.1 Ultrasonic Machining......Page 352
  10.1.1 Mechanism of Material Removal......Page 354
  10.1.2 Solved Example......Page 357
  10.1.3 Factors Affecting Material Removal Rate......Page 359
  10.1.5 Surface Quality......Page 365
  10.1.6 Applications......Page 367
 10.2 Abrasive Jet Machining......Page 368
  10.2.1 Material Removal Rate......Page 369
  10.2.2 Applications......Page 373
 10.3 Abrasive Water Jet Machining......Page 374
  10.3.1 Process Characteristics......Page 376
 10.4 Abrasive Flow Machining......Page 380
 10.5 Problems......Page 383
 10.6 Review Questions......Page 385
 11.2 Magnetic Abrasive Finishing......Page 386
  11.2.1 Process Description......Page 388
   11.2.2.1 Material Removal Rate and Surface Finish......Page 389
   11.2.2.2 Applications......Page 391
 11.3 Magnetic Float Polishing......Page 393
 11.5 Magnetorheological Abrasive Flow Finishing......Page 394
 11.6 Review Questions......Page 396
  12.2.1 Media......Page 398
  12.3.1 Barrel Finishing......Page 402
  12.3.2 Vibratory Finishing......Page 404
  12.3.3 Centrifugal Barrel Finishing......Page 405
  12.3.4 Centrifugal Disc Finishing......Page 406
  12.3.5 Spindle Finishing......Page 407
  12.4.1 Machining Principles......Page 409
  12.4.2 Factors Affecting Material Removal......Page 410
 12.5 Electropolishing......Page 411
 12.6 Review Questions......Page 413
 13.2 Principles of ECM......Page 416
 13.4 Material Removal Rate by ECM......Page 418
 13.5 Solved Example......Page 425
 13.6 ECM Equipment......Page 426
 13.7 Process Characteristics......Page 428
 13.8 Economics of ECM......Page 430
 13.9 ECM Applications......Page 432
 13.10 Chemical Machining......Page 437
 13.11 Solved Example......Page 439
 13.12 Problems......Page 440
 13.13 Review Questions......Page 442
  14.2.1 Mechanism of Material Removal......Page 444
  14.2.2 EDM Machine......Page 449
  14.2.3 Material Removal Rates......Page 453
  14.2.4 Surface Integrity......Page 454
  14.2.5 Heat-Affected Zone......Page 455
  14.2.6 Applications......Page 456
 14.3 Laser Beam Machining......Page 458
  14.3.1 Material Removal Mechanism......Page 459
  14.3.3 Applications......Page 462
 14.4 Electron Beam Machining......Page 465
  14.4.1 Material Removal Process......Page 466
  14.4.2 Solved Example......Page 468
  14.4.3 Applications......Page 471
 14.6 Plasma Beam Machining......Page 474
  14.6.1 Material Removal Rate......Page 477
  14.6.2 Applications......Page 479
 14.7 Problems......Page 480
 14.8 Review Questions......Page 481
  15.2.1 Electrochemical Grinding......Page 482
  15.2.2 Electrochemical Honing......Page 485
  15.2.4 Electrochemical Buffing......Page 486
 15.3 Hybrid Thermal Processes......Page 487
  15.3.1 Electroerosion Dissolution Machining......Page 488
  15.3.3 Abrasive Electrodischarge Machining......Page 490
  15.3.4 EDM with Ultrasonic Assistance......Page 492
  15.3.6 Brush Erosion Dissolution Mechanical Machining......Page 493
 15.4 Problems......Page 494
 15.5 Review Questions......Page 495
 16.2 Conventional Micromachining......Page 496
  16.2.1 Diamond Microturning......Page 497
  16.3.1 Microgrinding......Page 499
  16.3.2 Magnetic Abrasive Microfinishing......Page 500
  16.3.5 Micro-Ultrasonic Machining......Page 501
  16.4.1 Micromachining by Thermal Erosion......Page 502
   16.4.1.1 Micro-EDM......Page 503
   16.4.1.2 Laser Micromachining......Page 506
  16.4.2 Micromachining by Electrochemical Erosion......Page 507
   16.4.3.1 Chemical-Assisted Mechanical Polishing......Page 510
   16.4.3.3 Electrolytic In-process Dressing of Grinding Wheels......Page 511
 16.5 Review Questions......Page 512
 17.2 Reinforcing Materials......Page 514
 17.3 Matrix......Page 518
 17.4 Machining of Composites......Page 519
 17.5 Chip Formation......Page 520
  17.5.2 Cutting Unidirectional Composites......Page 521
   17.5.2.1 Sharp-Edged Tools......Page 522
  17.5.3 Cutting Multidirectional Composites......Page 525
  17.6.1 Turning......Page 526
  17.6.2 Drilling......Page 528
  17.6.3 Milling and Trimming......Page 531
  17.6.4 Grinding......Page 532
  17.7.1 Abrasive Water Jet Machining......Page 533
  17.7.2 Laser Beam Machining......Page 534
  17.7.3 Electrodischarge Machining......Page 535
 17.9 Problems......Page 536
 17.10 Review Questions......Page 537
  18.2.1 1-D VAM......Page 538
  18.2.2 2-D VAM......Page 541
 18.3 Advantages of VAM......Page 543
  18.4.1 Turning......Page 544
  18.4.2 Drilling......Page 545
  18.4.3 Milling......Page 546
  18.4.4 Grinding......Page 547
  18.5.1 Electrodischarge Machining......Page 548
  18.5.2 Electrochemical Machining......Page 549
  18.5.3 Abrasive Waterjet Machining......Page 550
 18.6 Review Questions......Page 551
  19.2.1 Judging Machinability......Page 552
  19.2.2 Relative Machinability......Page 554
  19.2.3 Factors Affecting Machinability......Page 555
   19.2.3.1 Condition of Work Material......Page 556
   19.2.3.3 Machining Parameters......Page 557
   19.2.4.1 Machinability of Steels and Alloy Steels......Page 558
   19.2.4.2 Machinability of Cast Irons......Page 560
   19.2.4.3 Machinability of Nonferrous Metals and Alloys......Page 561
   19.2.4.4 Machinability of Nonmetallic Materials......Page 562
 19.3 Nonconventional Machining......Page 563
 19.4 Review Questions......Page 569
  20.2.1 Part Features......Page 570
  20.2.3 Dimensional and Geometric Features......Page 572
  20.2.4 Surface Texture......Page 574
  20.2.5 Surface Integrity......Page 579
  20.2.6 Production Quantity......Page 580
  20.2.8 Environmental Impacts......Page 584
  20.2.9 Process and Machine Capability......Page 587
 20.3 Review Questions......Page 588
References......Page 590
Subject Index......Page 594