Precision Engineering

Contents......Page 13
Preface......Page 9
Acknowledgements......Page 11
1.1 Introduction to Precision Engineering......Page 19
1.2 The Difference between Accuracy and Precision......Page 20
1.4 Developmental Perspective of Machining Precision......Page 24
1.6 Normal Machining......Page 26
1.6.1 Gear Manufacture by Normal Machining......Page 30
1.7.1 Machining of Integrated Circuit Chips on a CNC Milling Machine for Failure Analysis......Page 33
1.7.2 Precision Manufacture of Spherical and Aspheric Surfaces on Plastics and Glass......Page 35
1.8 High-precision Machining......Page 40
1.9 Ultra-precision Machining......Page 43
1.9.1 Ultra-precision Processes and Nanotechnology......Page 45
1.11 References......Page 48
1.12 Review Questions......Page 49
2.1 Introduction......Page 51
2.2.1 Laminated Carbides......Page 54
2.2.2 CVD Coated Carbides......Page 55
2.2.4 Coating of the Second Generation of TiC (Cermets)......Page 59
2.2.5 PVD Coated Carbides......Page 61
2.3 Ceramics......Page 63
2.3.1 Hot-pressed Ceramics......Page 65
2.3.2 Silicon Nitride Ceramics......Page 66
2.4 Diamonds......Page 67
2.4.1 Crystallographic Planes......Page 68
2.4.3 Synthetic Diamonds......Page 74
2.4.4 Polycrystalline Diamond (PCD)......Page 76
2.4.5 Single-crystal Diamond (SPSCD)......Page 77
2.4.6 Diamond Coated Tools......Page 78
2.4.7 Design of Diamond Tools......Page 83
2.5 Cubic Boron Nitride (CBN)......Page 85
2.5.1 Coated CBN......Page 91
2.6 Tool and Work Material Compatibility......Page 93
2.7 References......Page 95
2.8 Review Questions......Page 97
3.1 Introduction......Page 98
3.2 An Overview of the Turning Operation and Tool Signature......Page 99
3.2.1 Single-point Cutting Tools......Page 100
3.3 Mechanics of Conventional Metal Cutting......Page 103
3.3.2 Chip Formation and Cutting Forces in Metal Cutting......Page 104
3.3.3 Merchant’s Theory......Page 108
3.3.4 Merchant’s Shear Angle......Page 109
3.3.5 Merchant’s Modified Shear Angle (Bridgman’s Theory)......Page 111
3.3.6 Merchant’s Strain Equation......Page 112
3.3.8 A Graphical Method to Construct Merchant’s Circle......Page 114
3.3.9 Mechanics of Oblique Cutting......Page 117
3.4.1 Basic Mechanics of Grinding—Material Removal Mechanism......Page 126
3.4.2 Grit Depth of Cut......Page 128
3.4.3 Specific Energy......Page 132
3.4.4 Temperature During Grinding......Page 134
3.4.5 Grinding Wheel Wear......Page 135
3.4.6 Truing and Dressing of Grinding Wheels......Page 136
3.5 Material Removal Mechanisms in Brittle Materials......Page 138
3.5.1 Ductile Mode Machining of Hard and Brittle Materials......Page 142
3.5.2 Models for Ductile Mode Machining of Brittle Materials......Page 144
3.6 References......Page 156
3.7 Review Questions......Page 158
4.1 Introduction......Page 160
4.2.1 Bonding Materials......Page 161
4.2.2 Abrasive Types......Page 162
4.2.3 Grit Size......Page 163
4.2.6 Concentration......Page 164
4.2.7 Design and Selection of the Grinding Wheel......Page 166
4.2.8 Mounted Wheels......Page 168
4.2.9 Bondless Diamond Grinding Wheel......Page 169
4.3 Conventional Grinding......Page 173
4.4.1 Jig Grinding for IC Chip Manufacturing......Page 177
4.4.2 Precision Grinding with Electrolytic In-process Dressing (ELID)......Page 181
4.4.3 Various Methods for Generating an Aspheric Surface......Page 183
4.5.1 Various Ultra-precision Machines and Their Development......Page 192
4.5.2 Some Applications of Ultra-precision Machining......Page 198
4.6 References......Page 200
4.7 Review Questions......Page 204
5.1 Introduction......Page 205
5.2 Guideways......Page 210
5.3.1 Nut and Screw Transmission......Page 215
5.3.2 Friction Drive......Page 219
5.3.3 Linear Motor Drive......Page 222
5.4 Spindle Drive......Page 230
5.5 Preferred Numbers......Page 231
5.7 Review Questions......Page 234
6.1 Introduction......Page 237
6.2.1 Principle of Rolling Element Bearings......Page 238
6.2.3 Classification of Rolling Element Bearings......Page 239
6.2.4 Application of Rolling Element Bearings......Page 243
6.2.5 Selection of Rolling Element Bearings......Page 244
6.2.6 Fitting of Rolling Element Bearings......Page 245
6.2.7 Bearing Life......Page 249
6.3 Lubricated Sliding Bearings......Page 254
6.3.2 Principle of Lubrication......Page 255
6.3.3 Principle of Hydrodynamic Bearings......Page 258
6.3.4 Comparison and Selection Between Rolling and Sliding Bearings......Page 259
6.3.5 Hydrodynamic Thrust Bearings......Page 263
6.3.6 Application of Hydrodynamic Bearings......Page 264
6.3.7 Mathematical Approximation of Hydrodynamic Bearings......Page 268
6.4 Hydrostatic Bearings......Page 271
6.4.2 Construction of Hydrostatic Bearings......Page 272
6.4.3 Classification of Hydrostatic Bearings......Page 275
6.4.4 Operation of a Hydrostatic Bearing System......Page 277
6.4.5 Advantages and Disadvantages of Hydrostatic Bearings......Page 279
6.4.6 Application of Hydrostatic Bearings......Page 280
6.4.7 Mathematical Approximation of Hydrostatic Bearings......Page 282
6.4.8 Design of Hydrostatic Bearings......Page 286
6.5 Hybrid Fluid Bearings......Page 299
6.6 References......Page 300
6.7 Review Questions......Page 301
7.1 Introduction......Page 305
7.2 Aerodynamic Bearings......Page 306
7.3.1 Principle of Aerostatic Bearings......Page 307
7.3.2 Construction of Aerostatic Bearings......Page 309
7.3.3 Classification of Aerostatic Bearings......Page 311
7.3.4 Operation of Aerostatic Bearing Systems......Page 314
7.3.5 Advantages and Disadvantages of Aerostatic Bearings......Page 316
7.3.6 Application and Principles of Aerostatic Bearings......Page 319
7.3.7 Aerostatic Spindles......Page 325
7.3.8 Mathematical Approximation of Aerostatic Bearings......Page 328
7.3.9 Theory of Aerostatic Lubrication......Page 330
7.3.10 Design of Aerostatic Journal Bearings......Page 336
7.3.11 Thrust Bearings......Page 355
7.4 Hybrid Gas Bearings......Page 363
7.5 Comparison of Bearing Systems......Page 367
7.6 Material Selection for Bearings......Page 374
7.7 References......Page 379
7.8 Review Questions......Page 380
8.1 Introduction......Page 384
8.2 Advances in Microelectronics......Page 385
8.3 Characteristics and Principles of MEMS......Page 386
8.4 Design of MEMS......Page 390
8.5 Application of MEMS......Page 397
8.5.1 Application of MEMS in Automobiles......Page 398
8.5.2 Application of MEMS in the Health-care Industry......Page 402
8.5.3 Application of MEMS in Defence......Page 403
8.5.5 Application of MEMS in Industrial Products......Page 404
8.6 Materials for MEMS......Page 405
8.7 MEMS Fabrication and Micromanufacturing Processes......Page 407
8.7.1 Bulk Micromachining......Page 408
8.7.2 Surface Micromachining......Page 411
8.7.3 LIGA Process......Page 413
8.8 MEMS and Microsystem Packaging......Page 415
8.9 Future of MEMS......Page 416
8.10 Clean Rooms......Page 417
8.10.1 Effects of Various Parameters......Page 418
8.10.2 The Design and Construction of Clean Rooms......Page 422
8.11 References......Page 424
8.12 Review Questions......Page 425
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