Fundamentals of machining and machine tools

CONVENTIONS USED IN THIS BOOK Standardization Introduction to the International (SI) System of Units MACHINE TOOLS AND MACHINING OPERATIONS Introduction Generating Motions of Machine Tools Machines Using Single-Point Tools Machines Using Multipoint Tools Machines Using Abrasive Wheels Summary of Machine Tool Characteristics and Machining Equations Problems References MECHANICS OF METAL CUTTING Introduction Terms and Definitions Chip Formation The Forces Acting on the Cutting Tool and Their Measurement Specific Cutting Energy Plowing Force and the Size The Apparent Mean Shear Strength of the Work Material Chip Thickness Friction in Metal Cutting Analytical Modeling of Machining Operations Problems References TEMPERATURES IN METAL CUTTING Heat Generation in Metal Cutting Heat Transfer in a Moving Material Temperature Distribution in Metal Cutting The Measurement of Cutting Temperatures Problems References TOOL LIFE AND TOOL MATERIALS Introduction Progressive Tool Wear Forms of Wear in Metal Cutting The Tool Material Tool Geometries The Work Material High Speed Machining Hard Machining Problems References CUTTING FLUIDS AND SURFACE ROUGHNESS Cutting Fluids The Action of Coolants The Action of Lubricants Application of Cutting Fluids Cutting Fluid Maintenance Environmental Considerations Disposal of Cutting Fluids Dry Cutting and Minimum Quantity Lubrication Surface Roughness Tool Geometries for Improved Surface Finish Burr Formation in Machining Problems References ECONOMICS OF METAL-CUTTING OPERATIONS Introduction Choice of Feed Choice of Cutting Speed Tool Life for Minimum Cost and Minimum Production Time Estimation of Factors Needed to Determine Optimum Conditions Example of a Constant-Cutting-Speed Operation Machining at Maximum Efficiency Facing Operations Operations with Interrupted Cuts Economics of Various Tool Materials and Tool Designs Machinability Data Systems Limitations of Available Machinability Data Problems References NOMENCLATURE OF CUTTING TOOLS Introduction Systems of Cutting-Tool Nomenclature International Standard Problems References CHIP CONTROL Introduction Chip Breakers Prediction of Radius of Chip Curvature Prediction of Chip Breaking Performance Tool Wear During Chip Breaking Problems References MACHINE TOOL VIBRATIONS Introduction Forced Vibrations Self-Excited Vibrations (Chatter) Determination of Frequency Response Loci Dynamic Acceptance Tests for Machine Tools Improving Machine Tool Stability Problems References GRINDING Introduction The Grinding Wheel Effect of Grinding Conditions on Wheel Behavior Determination of the Density of Active Grains Testing of Grinding Wheels Dressing and Truing of Grinding Wheels Analysis of the Grinding Process Thermal Effects in Grinding Cutting Fluids in Grinding Grinding-Wheel Wear Nonconventional Grinding Operations Problems References MANUFACTURING SYSTEMS AND AUTOMATION Introduction Types of Production Types of Facilities Layout Types of Automation Transfer Machines Automatic Machines Numerically Controlled (NC) Machine Tools Comparison of the Economics of Various Automation Systems Handling of Components in Batch Production Flexible Manufacturing Systems Problems References COMPUTER-AIDED MANUFACTURING Introduction Scope of CAD/CAM Process-Planning Tasks Computer-Aided Process Planning Processing of NC Programs Computer-Aided NC Processing Numerical Control Processing Languages NC Programming Using APT-Based Languages Graphics-Based NC Processing Systems References DESIGN FOR MACHINING Introduction Standardization Choice of Work Material Shape of Work Material Shape of Component Assembly of Components Accuracy and Surface Finish Summary of Design Guidelines Cost Estimating for Machined Components Problems References NONCONVENTIONAL MACHINING PROCESSES Introduction Range of Nonconventional Machining Processes Ultrasonic Machining Water-Jet Machining Abrasive-Jet Machining Chemical Machining Electrochemical Machining Electrolytic Grinding Electrical-Discharge Machining Wire Electrical-Discharge Machining Laser-Beam Machining Electron-Beam Machining Plasma-Arc Cutting Comparative Performance of Cutting Processes Problems References NOMENCLATURE INDEX