Non-Traditional and Advanced Machining Technologies: Machine Tools and Operations

Cover
Half Title
Title Page
Copyright Page
Dedication
Table of Contents
Preface
Acknowledgements
Author Biographies
List of Symbols
List of Acronyms
Unit I Non-Traditional Machining Operations and Non-Traditional Machine Tools
	Chapter 1 Non-Traditional Machining Processes
		1.1 Introduction
		1.2 Classification of Non-Traditional Machining Processes
		1.3 Review Questions
		References
	Chapter 2 Mechanical Non-Traditional Machining Operations and Machine Tools
		2.1 Jet Machines and Operations
			2.1.1 Abrasive Jet Machining
				2.1.1.1 Process Characteristics and Applications
				2.1.1.2 Work Station of Abrasive Jet Machining
				2.1.1.3 Process Capabilities
			2.1.2 Water Jet Machining (Hydrodynamic Machining)
				2.1.2.1 Process Characteristics and Applications
				2.1.2.2 Equipment of WJM
				2.1.2.3 Process Capabilities
			2.1.3 Abrasive Water Jet Machining
				2.1.3.1 Process Characteristics and Applications
				2.1.3.2 AWJM Equipment
				2.1.3.3 Process Capabilities
		2.2 Ultrasonic Machining
			2.2.1 Definition, Characteristics, and Applications
			2.2.2 USM Equipment
			2.2.3 Design of Acoustic Horns
				Magnification Factor Rm
			2.2.4 Process Capabilities
			2.2.5 Recent Developments
		2.3 Abrasive Flow Machining
			2.3.1 Principles
			2.3.2 Process Parameters of Abrasive Flow Machining
			2.3.3 Applications of AFM
		2.4 Review Questions and Problems
		References
	Chapter 3 Chemical and Electrochemical Non-Traditional Machining Operations and Machine Tools
		3.1 Chemical Machining
			3.1.1 Chemical Milling
				Tooling for CH Milling
				Advantages and Disadvantages of CH Milling
			3.1.2 Photochemical Machining (Spray Etching)
				Applications of PCM Process
				Advantages and Disadvantages of PCM
		3.2 Electrochemical Machines and Operations
			3.2.1 Process Characteristics and Applications
				Advantages of ECM
				Disadvantages of ECM
				Applications of ECM
			3.2.2 Elements of ECM
			3.2.3 ECM Equipment (EC Sinking Machine)
			3.2.4 Process Capabilities
			3.2.5 ECM Allied Processes
				3.2.5.1 Shaped Tube Electrolytic Machining
				3.2.5.2 Electrostream (Capillary) Drilling
				3.2.5.3 Electrochemical Jet Drilling
				3.2.5.4 Electrochemical Deburring
				3.2.5.5 Electrochemical Polishing
				3.2.5.6 Electrochemical Sharpening
				3.2.5.7 Electrochemical Grinding
				3.2.5.8 Electrochemical Honing
		3.3 Review Questions and Problems
		References
	Chapter 4 Thermo-Electrical Non-Traditional Machining Operations and Machine Tools
		4.1 Electrical Discharge Machines and Operations
			4.1.1 Process Characteristics and Applications
				Applications
			4.1.2 Sinking Machine
			4.1.3 EDM-Spark Circuits (Power Supply Circuits)
				4.1.3.1 Resistance-Capacitance RC Circuit
				4.1.3.2 Transistorized Pulse Generator Circuits
			4.1.4 EDM Tool Electrodes
			4.1.5 Process Capabilities
			4.1.6 EDM Allied Processes
				4.1.6.1 Electrical Discharge Milling (ED Milling)
				4.1.6.2 Electrical Discharge Wire Cutting
		4.2 Electron Beam Machining Equipment and Operations
			4.2.1 Process Characteristics and Applications
			4.2.2 Electron Beam Machining Equipment
			4.2.3 Process Capabilities
		4.3 Laser Beam Machining Equipment and Operations
			4.3.1 Process Characteristics
				Process Advantages and Limitations
			4.3.2 Types of Lasers
				4.3.2.1 Pyrolithic and Photolithic Lasers
				4.3.2.2 Industrial Lasers
			4.3.3 Laser Beam Machining Operations
			4.3.4 LBM Equipment
			4.3.5 Applications and Capabilities
		4.4 Plasma Arc Cutting Systems and Operations
			4.4.1 Process Characteristics
			4.4.2 Plasma Arc Cutting Systems
			4.4.3 Applications and Capabilities of PAC
		4.5 Review Questions and Problems
		References
Unit II Advanced Machining Technology
	Chapter 5 Machining of DTC Materials (Stainless Steels and Super Alloys) by Traditional and Non-Traditional Methods
		5.1 Introduction
		5.2 Traditional Machining of Stainless Steels
			5.2.1 Types, Characteristics, and Applications of SSs
			5.2.2 Machinability and Machinability Ratings of SSs
				5.2.2.1 Free-Machining Additives of Stainless Steels
				5.2.2.2 Machinability of Free- and Non-Free-Machining Stainless Steels
				5.2.2.3 Enhanced Machining Stainless Steels
				5.2.2.4 Machinability Ratings of Stainless Steels
			5.2.3 Machining and Machining Conditions of SSs
		5.3 Traditional Machining of Super Alloys
			5.3.1 Types, Characteristics, and Applications of SAs
			5.3.2 Machinability and Machinability Rating of Super Alloys
				5.3.2.1 Machinability Aspects of Super Alloys
				5.3.2.2 Machinability Rating of Super Alloys
			5.3.3 Machining and Machining Conditions of Super Alloys
		5.4 Non-Traditional Machining of Stainless Steels and Super Alloys
			5.4.1 Machining of Stainless Steels and Super Alloys by Mechanical Techniques
			5.4.2 Machining SSs and SAs by Electrochemical and Chemical Techniques
			5.4.3 Thermoelectric Machining of Stainless Steels and Super Alloys
		5.5 Review Questions
		References
	Chapter 6 Machining of DTC Materials (Ceramics and Composites) by Traditional and Non-Traditional Methods
		6.1 Introduction
		6.2 Machining of Ceramic Materials
			6.2.1 Ceramic as a Promising Engineering Material
			6.2.2 Types, Characteristics, Classification, and Applications of Ceramics
				6.2.2.1 Types, Characteristics, and Classification
				6.2.2.2 Fields of Applications
			6.2.3 Fabrication Techniques of Crystalline Ceramics
				6.2.3.1 Processing Techniques and Shaping of Green Bodies
				6.2.3.2 Green Machining Processes of Green and Pre-Sintered Ceramics
				6.2.3.3 Hard Machining Processes of Sintered Ceramics
		6.3 Machining of Composite Materials
			6.3.1 Types, Characteristics, and Applications of Composites
			6.3.2 Traditional Machining and Machinability of Composites
			6.3.3 Non-Traditional Machining and Machinability of Composites
		6.4 Review Questions
		References
	Chapter 7 Assisted Machining Technologies
		7.1 Introduction
		7.2 Thermal-Assisted Machining
			7.2.1 Laser-Assisted Machining
			7.2.2 Plasma-Assisted Machining
		7.3 Vibration-Assisted Machining (VAM)
			7.3.1 Principles and Aims of VAM
			7.3.2 Vibration-Assisted Traditional Machining Processes
				7.3.2.1 Vibration-Assisted Turning
				7.3.2.2 Vibration-Assisted Drilling
				7.3.2.3 Vibration-Assisted Milling
				7.3.2.4 Vibration-Assisted Grinding
			7.3.3 Vibration-Assisted Non-Traditional Machining Processes
				7.3.3.1 Vibration-Assisted Electrochemical Machining (VAECM)
				7.3.3.2 Vibration-Assisted Electrodischarge Machining
				7.3.3.3 Vibration-Assisted Laser Beam Machining
				7.3.3.4 Vibration-Assisted Abrasive Water Jet Machining
		7.4 Magnetic Field-Assisted Processes
			7.4.1 Magnetic Abrasive Finishing (MAF)
				7.4.1.1 Finishing of Outer Cylindrical Surfaces and Typical Machining Conditions of MAF
				7.4.1.2 MAF Finishing of Inner Cylindrical Surfaces
				7.4.1.3 Semi-Magnetic Abrasive Finishing (SMAF)
				7.4.1.4 Other MAF Applications
			7.4.2 Magnetic Float Polishing (MFP) or Magnetic Fluid Grinding (MFG)
			7.4.3 Advantages of MFAP
			7.4.4 Magnetorheological Finishing (MRF)
			7.4.5 Magnetorheological Abrasive Flow Finishing (MRAFF)
		7.5 Review Questions
		References
	Chapter 8 Design for Machining
		8.1 Introduction
			8.1.1 General Design Rules
		8.2 General Design Recommendations
		8.3 Design for Machining by Cutting
			8.3.1 Turning
				8.3.1.1 Economic Production Quantities
				8.3.1.2 Design Recommendations for Turning
				8.3.1.3 Dimensional Control
			8.3.2 Drilling and Allied Operations
				8.3.2.1 Economic Production Quantities
				8.3.2.2 Design Recommendations for Drilling and Allied Operations
				8.3.2.3 Dimensional Control
			8.3.3 Milling
				8.3.3.1 Design Recommendations
				8.3.3.2 Dimensional Factors and Tolerances
			8.3.4 Shaping, Planing, and Slotting
				8.3.4.1 Design Recommendations
				8.3.4.2 Dimensional Control
			8.3.5 Broaching
				8.3.5.1 Design Recommendations
				8.3.5.2 Dimensional Factors
				8.3.5.3 Recommended Tolerances
			8.3.6 Thread Cutting
				8.3.6.1 Design Recommendations
				8.3.6.2 Dimensional Factors and Tolerances
			8.3.7 Gear Cutting
				8.3.7.1 Design Recommendations
				8.3.7.2 Dimensional Factors
		8.4 Design for Grinding
			8.4.1 Surface Grinding
				8.4.1.1 Design Recommendations
				8.4.1.2 Dimensional Control
			8.4.2 Cylindrical Grinding
				8.4.2.1 Design Recommendations
				8.4.2.2 Dimensional Factors
			8.4.3 Centerless Grinding
				8.4.3.1 Design Recommendations
				8.4.3.2 Dimensional Control
		8.5 Design for Abrasive Finishing Processes
			8.5.1 Honing
			8.5.2 Lapping
			8.5.3 Superfinishing
		8.6 Design for Chemical and Electrochemical Machining
			8.6.1 Chemical Machining
				8.6.1.1 Design Recommendations
				8.6.1.2 Dimensional Factors and Tolerances
			8.6.2 Electrochemical Machining
				8.6.2.1 Design Recommendations
				8.6.2.2 Dimensional Factors
			8.6.3 Electrochemical Grinding
				8.6.3.1 Design Recommendations
				8.6.3.2 Dimensional Factors
		8.7 Design for Thermal Machining
			8.7.1 Electrodischarge Machining
				8.7.1.1 Design Recommendations
				8.7.1.2 Dimensional Factors
			8.7.2 Electron Beam Machining
			8.7.3 Laser Beam Machining
		8.8 Design for Ultrasonic Machining
		8.9 Design for Abrasive Jet Machining
		8.10 Review Questions
		References
	Chapter 9 Accuracy and Surface Integrity Realized by Machining Processes
		9.1 Introduction
		9.2 Surface Texture
		9.3 Surface Quality and Functional Properties
		9.4 Surface Integrity
		9.5 Surface Effects by Traditional Machining
			9.5.1 Chip Removal Processes
			9.5.2 Grinding
		9.6 Surface Effects by Non-Traditional Machining
			9.6.1 Electrochemical and Chemical Machining
			9.6.2 Thermal Non-Traditional Processes
				9.6.2.1 Electrodischarge Machining
				9.6.2.2 Laser Beam Machining
				9.6.2.3 Electron Beam Machining
				9.6.2.4 Plasma Beam Machining (PBM)
				9.6.2.5 Electroerosion Dissolution Machining
				9.6.2.6 Electrochemical Discharge Grinding
			9.6.3 Mechanical Non-Traditional Processes
		9.7 Reducing Distortion and Surface Effects in Machining
		9.8 Review Questions
		References
	Chapter 10 Environment-Friendly Machine Tools and Operations
		10.1 Introduction
		10.2 Traditional Machining
			10.2.1 Cutting Fluids
				10.2.1.1 Classification of Cutting Fluids
				10.2.1.2 Selection of Cutting Fluids
				10.2.1.3 Evaluation of Cutting Fluids
			10.2.2 Hazard Ranking of Cutting Fluids
			10.2.3 Health Hazards of Cutting Fluids
			10.2.4 Cryogenic Cooling
			10.2.5 Ecological Machining
			10.2.6 Factors Affecting the Use of MQL
			10.2.7 Applications of Ecological Machining
		10.3 Non-Traditional Machining Processes
			10.3.1 Chemical Machining
			10.3.2 Electrochemical Machining
			10.3.3 Electrodischarge Machining
				10.3.3.1 Protective Measures
			10.3.4 Laser Beam Machining
			10.3.5 Ultrasonic Machining
				10.3.5.1 Electromagnetic Field
				10.3.5.2 Ultrasonic Waves
				10.3.5.3 Abrasives Slurry
				10.3.5.4 Contact Hazards
				10.3.5.5 Other Hazards
			10.3.6 Abrasive Jet Machining
		10.4 Review Questions
		References
	Chapter 11 Hexapods and Machining Technology
		11.1 Introduction
		11.2 Historical Background
		11.3 Hexapod Mechanism and Design Features
			11.3.1 Hexapod Mechanism
			11.3.2 Design Features
				11.3.2.1 Hexapods of Telescopic Struts (Ingersoll System)
				11.3.2.2 Hexapods of Ball Screw Struts (Hexel and Geodetic System)
		11.4 Hexapod Constructional Elements
			11.4.1 Strut Assembly
			11.4.2 Sphere Drive
			11.4.3 Bifurcated Balls
			11.4.4 Spindles
			11.4.5 Articulated Head
			11.4.6 Upper Platform
			11.4.7 Control System
		11.5 Hexapod Characteristics
		11.6 Manufacturing Applications
		11.7 Review Questions
		References
Index