Metal cutting and design of cutting tools, jigs & fixtures

Title
Contents
1. Introduction to Machining Process
	1.1 Introduction
		1.1.1 Basics of Metal Cutting
			1.1.2 Working and Auxiliary Motions in Machine Tools
	1.2 Concept of Speed, Feed, Depth of Cut, and Machining Time
	1.3 Lathe Operations
	1.4 Drilling and Allied Operations
	1.5 Milling Operations
		1.5.1 Indexing Based on Periodic Rotation
			1.5.2 Indexing Based on Continuous Rotation
	1.6 Shaping and Allied Operations
	1.7 Grinding Operations
		1.7.1 External Cylindrical Grinding
			1.7.2 Internal Cylindrical Grinding
			1.7.3 Surface Grinding
	1.8 Geometry of Single-Point Tool
		1.8.1 Orthogonal System
			1.8.2 Machine Tool Reference System
			Review Questions
2. Geometry of Chip Formation
	2.1 Process of Chip Formation
	2.2 Parameters of Undeformed Chip in Turning, Drilling, and Milling
		2.2.1 Undeformed Chip in Turning
		2.2.2 Undeformed Chip in Drilling
		2.2.3 Undeformed Chip in Plain Milling
		2.2.4 Undeformed Chip in Face Milling
	2.3 Shear Angle and Shear Strain in Chip Formation
		2.3.1 Shear Angle
		2.3.2 Shear Strain
	2.4 Types of Chips
		2.4.1 Discontinuous Chips
		2.4.2 Continuous Chips
		2.4.3 Partially Continuous Chips
		2.4.4 Element Chips
		2.5 Chip Flow Control and Chip Breaking
			2.5.1 Control of Chip Flow
				2.5.2 Chip Breaking
				Review Questions
3. Mechanics of Machining Process
	3.1 Orthogonal and Oblique Machining
	3.2 Force Velocity and Energy Relations in Orthogonal Machining
		3.2.1 Force Relations
			3.2.2 Velocity Relations
			3.2.3 Energy Relations
	3.3 Theoretical Determination of Cutting Force
		3.3.1 Determination of Dynamic Shear Stress
			3.3.2 Shear Angle Relations
			3.3.3 Forces in Drilling
			3.3.4 Forces in Milling
	3.4 Built-Up Edge
		3.4.1 Characteristic Features of BUE
	3.5 Effect of Tool Geometry and Machining Parameters on Cutting Force
		Review Questions
4. Tool Wear and Thermodynamics of Chip Formation
	4.1 Heat Sources and Its Distribution
	4.2 Tool Failure and Tool Wear
	4.3 Growth of Tool Wear with Cutting Time, Wear Criteria, and Wear Mechanisms
		4.3.1 Tool Wear Criteria
			4.3.2 Tool Wear Mechanisms
	4.4 Tool Life and Machinability
	4.5 Tool Life Testing
		4.5.1 Facing Test
			4.5.2 Variable Speed Test
	4.6 Effect of Various Factors on Tool Life
		4.6.1 Effect of Work Material
			4.6.2 Effect of Tool Material
			4.6.3 Effect of Tool Geometry
	4.7 Machinability
		4.7.1 Surface Finish
		4.7.2 Machinability Index
	4.8 Theoretical Determination of Cutting Temperature
		4.8.1 Temperature Relations for Various Heat Sources
		4.8.2 Shear Plane Temperature
		4.8.3 Tool–chip Interface Temperature and Cutting Temperature
	4.9 Economics of Machining
		4.9.1 Sequence of Assigning the Machining Parameters
		4.9.2 Selection of Depth of Cut
		4.9.3 Selection of Feed
		4.9.4 Selection of Optimum Cutting Speed
		Review Questions
5. Geometry of Cutting Tools
	5.1 Issues in Geometry of Single-Point Tools
		5.1.1 Effect of Tool Setting and Feed on Rake and Clearance Angles
		5.1.2 Selection of Optimum Tool Angles
	5.2 Geometry of Form Tool
	5.3 Geometry of Drill
	5.4 Geometry of Milling Cutters
		5.4.1 Geometry of Plain Milling Cutter
		5.4.2 Geometry of Face Milling Cutter
	5.5 Geometry of Broach
	5.6 Geometry of Thread Cutting Tools
		5.6.1 Geometry of Single-Point Thread Cutting Tool
		5.6.2 Geometry of Thread Chasers
		5.6.3 Geometry of Thread Cutting Taps
		5.6.4 Geometry of Thread-Cutting Die
	5.7 Geometry of Gear Cutting Tools
		Review Questions
6. Design of Cutting Tools
	6.1 Design of Single-Point Tool
		6.1.1 Features Related to Cutting Bit
	6.2 Design of Form Tool
		6.2.1 Design of Circular Form Tool
		6.2.2 Design of Flat Form Tool
	6.3 Design of Drills
	6.4 Design of Milling Cutters
		6.4.1 Design of Plain Milling Cutter
		6.4.2 Design of Face Milling Cutters
	6.5 Design of Broach
	6.6 Design of Thread Cutting Tools
		6.6.1 Design of Taps
		6.6.2 Design of Thread Cutting Dies
	6.7 Geometry and Design of Gear Cutting Tools
		6.7.1 Geometry and Design of Module Cutter
		6.7.2 Geometry and Design of Gear Shaping Cutter
		6.7.3 Geometry and Design of Hob
		Review Questions
7. Design of Jigs and Fixtures
	7.1 Introduction
	7.2 Location Principles, Methods, and Elements
		7.2.1 Concept of Design, Setting, and Measuring Datum Surfaces
			7.2.2 Locating Scheme, Error Analysis, and Elements for Prismatic Parts
			7.2.3 Locating Scheme, Error Analysis, and Elements for Long Cylindrical Parts
			7.2.4 Locating Scheme, Error Analysis, and Elements for Short Cylindrical Parts
			7.2.5 Locating Scheme, Error Analysis, and Elements for Parts with Through Hole
			7.2.6 Locating Scheme, Error Analysis, and Elements for Parts with Flat Base and Two Predrilled Holes
			7.2.7 Locating Scheme, Error Analysis, and Elements for Parts with Center Holes at End Faces
	7.3 Clamping Principles, Methods, and Elements
		7.3.1 Clamping Principles
		7.3.2 Clamping Force Calculation
		7.3.3 Clamping Mechanisms and Applied Force Calculation
		7.3.4 Clamping Elements and Devices
	7.4 Tool Guiding Elements
	7.5 Indexing Devices
	7.6 Body of Jigs and Fixtures
	7.7 Power Devices
		Review Questions
8. Classification of Jigs and Fixtures and Their Economic Analysis
	8.1 Classification of Jigs and Fixtures
		8.1.1 Universal General-Purpose Fixture(UGP)
		8.1.2 Universal Adjustable Fixture(UAF)
		8.1.3 Special Adjustable Fixture(SAF)
		8.1.4 Reassemblable Fixture(RAF)
		8.1.5 Universal Built-Up Fixture(UBF)
		8.1.6 Special Fixtures(SPF)
	8.2 Economics of Jigs and Fixtures
		8.2.1 Calculation of Annual Cost of Fixture
		8.2.2 Relative Economic Analysis
		Review Questions
Bibliography
Index