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Machining Technology and Operations: 2-Volume Set 2nd edition [Multiple-component retail product]

(Alexandria University, Egypt), (Egypt-Japan University of Science and Technology)
  • Formatas: Multiple-component retail product, 938 pages, aukštis x plotis: 234x156 mm, weight: 2000 g, 169 Tables, black and white; 855 Illustrations, black and white, Contains 2 hardbacks
  • Išleidimo metai: 11-Aug-2020
  • Leidėjas: CRC Press
  • ISBN-10: 0367431319
  • ISBN-13: 9780367431310
Kitos knygos pagal šią temą:
  • Formatas: Multiple-component retail product, 938 pages, aukštis x plotis: 234x156 mm, weight: 2000 g, 169 Tables, black and white; 855 Illustrations, black and white, Contains 2 hardbacks
  • Išleidimo metai: 11-Aug-2020
  • Leidėjas: CRC Press
  • ISBN-10: 0367431319
  • ISBN-13: 9780367431310
Kitos knygos pagal šią temą:

This two-volume set addresses both current and developing topics of advanced machining technologies and machine tools used in industry. The treatments are aimed at motiving and challenging the reader to explore viable solutions to a variety of questions regarding product design and optimum selection of machining operations for a given task. This two-volume set will be useful to professionals, students, and companies in the areas of mechanical, industrial, manufacturing, materials, and production engineering fields.

Traditional Machining Technology

covers the technologies, machine tools, and operations of traditional machining processes. These include the general-purpose machine tools used for turning, drilling, and reaming, shaping and planing, milling, grinding and finishing operations. Thread and gear cutting, and broaching processes are included along with semi-automatic, automatic, NC and CNC machine tools, operations, tooling, mechanisms, accessories, jigs and fixtures, and machine tool dynamometry are discussed.

Non-Traditional and Advanced Machining Technologies

covers the technologies, machine tools, and operations of non-traditional mechanical, chemical and thermal machining processes. Assisted machining technologies, machining of difficult-to-cut materials, design for machining, accuracy and surface integrity of machined parts, environment-friendly machine tools and operations, and hexapods are also presented. The topics covered throughout this volume reflect the rapid and significant advances that have occurred in various areas in machining technologies.

Preface xv
Acknowledgements xvii
Author Biographies xix
List of Symbols
xxi
List of Acronyms
xxiii
UNIT I Non-Traditional Machining Operations and Non-Traditional Machine Tools
Chapter 1 Non-Traditional Machining Processes
3(4)
1.1 Introduction
3(1)
1.2 Classification of Non-Traditional Machining Processes
4(1)
1.3 Review Questions
5(1)
References
6(1)
Chapter 2 Mechanical Non-Traditional Machining Operations and Machine Tools
7(56)
2.1 Jet Machines and Operations
7(21)
2.1.1 Abrasive Jet Machining
7(1)
2.1.1.1 Process Characteristics and Applications
7(2)
2.1.1.2 Work Station of Abrasive Jet Machining
9(1)
2.1.1.3 Process Capabilities
10(1)
2.1.2 Water Jet Machining (Hydrodynamic Machining)
11(1)
2.1.2.1 Process Characteristics and Applications
11(3)
2.1.2.2 Equipment of WJM
14(3)
2.1.2.3 Process Capabilities
17(1)
2.1.3 Abrasive Water Jet Machining
17(1)
2.1.3.1 Process Characteristics and Applications
17(4)
2.1.3.2 AWJM Equipment
21(5)
2.1.3.3 Process Capabilities
26(2)
2.2 Ultrasonic Machining
28(26)
2.2.1 Definition, Characteristics, and Applications
28(3)
2.2.2 USM Equipment
31(5)
2.2.3 Design of Acoustic Horns
36(14)
2.2.4 Process Capabilities
50(3)
2.2.5 Recent Developments
53(1)
2.3 Abrasive Flow Machining
54(6)
2.3.1 Principles
54(1)
2.3.2 Process Parameters of Abrasive Flow Machining
55(5)
2.3.3 Applications of AFM
60(1)
2.4 Review Questions and Problems
60(1)
References
61(2)
Chapter 3 Chemical and Electrochemical Non-Traditional Machining Operations and Machine Tools
63(36)
3.1 Chemical Machining
63(11)
3.1.1 Chemical Milling
63(7)
3.1.2 Photochemical Machining (Spray Etching)
70(4)
3.2 Electrochemical Machines and Operations
74(21)
3.2.1 Process Characteristics and Applications
74(3)
3.2.2 Elements of ECM
77(3)
3.2.3 ECM Equipment (EC Sinking Machine)
80(2)
3.2.4 Process Capabilities
82(1)
3.2.5 ECM Allied Processes
82(1)
3.2.5.1 Shaped Tube Electrolytic Machining
82(3)
3.2.5.2 Electrostream (Capillary) Drilling
85(2)
3.2.5.3 Electrochemical Jet Drilling
87(1)
3.2.5.4 Electrochemical Deburring
87(3)
3.2.5.5 Electrochemical Polishing
90(1)
3.2.5.6 Electrochemical Sharpening
91(1)
3.2.5.7 Electrochemical Grinding
92(2)
3.2.5.8 Electrochemical Honing
94(1)
3.3 Review Questions and Problems
95(2)
References
97(2)
Chapter 4 Thermo-Electrical Non-Traditional Machining Operations and Machine Tools
99(48)
4.1 Electrical Discharge Machines and Operations
99(17)
4.1.1 Process Characteristics and Applications
99(3)
4.1.2 Sinking Machine
102(3)
4.1.3 EDM-Spark Circuits (Power Supply Circuits)
105(1)
4.1.3.1 Resistance-Capacitance RC Circuit
105(3)
4.1.3.2 Transistorized Pulse Generator Circuits
108(1)
4.1.4 EDM Tool Electrodes
109(1)
4.1.5 Process Capabilities
110(2)
4.1.6 EDM Allied Processes
112(1)
4.1.6.1 Electrical Discharge Milling (ED Milling)
112(3)
4.1.6.2 Electrical Discharge Wire Cutting
115(1)
4.2 Electron Beam Machining Equipment and Operations
116(7)
4.2.1 Process Characteristics and Applications
116(2)
4.2.2 Electron Beam Machining Equipment
118(2)
4.2.3 Process Capabilities
120(3)
4.3 Laser Beam Machining Equipment and Operations
123(12)
4.3.1 Process Characteristics
123(2)
4.3.2 Types of Lasers
125(1)
4.3.2.1 Pyrolithic and Photolithic Lasers
125(1)
4.3.2.2 Industrial Lasers
125(2)
4.3.3 Laser Beam Machining Operations
127(4)
4.3.4 LBM Equipment
131(1)
4.3.5 Applications and Capabilities
132(3)
4.4 Plasma Arc Cutting Systems and Operations
135(4)
4.4.1 Process Characteristics
135(1)
4.4.2 Plasma Arc Cutting Systems
136(1)
4.4.3 Applications and Capabilities of PAC
137(2)
4.5 Review Questions and Problems
139(4)
References
143(4)
UNIT II Advanced Machining Technology
Chapter 5 Machining of DTC Materials (Stainless Steels and Super Alloys) by Traditional and Non-Traditional Methods
147(72)
5.1 Introduction
147(1)
5.2 Traditional Machining of Stainless Steels
147(19)
5.2.1 Types, Characteristics, and Applications of SSs
147(5)
5.2.2 Machinability and Machinability Ratings of SSs
152(1)
5.2.2.1 Free-Machining Additives of Stainless Steels
152(1)
5.2.2.2 Machinability of Free- and Non-Free-Machining Stainless Steels
153(2)
5.2.2.3 Enhanced Machining Stainless Steels
155(1)
5.2.2.4 Machinability Ratings of Stainless Steels
155(1)
5.2.3 Machining and Machining Conditions of SSs
156(10)
5.3 Traditional Machining of Super Alloys
166(25)
5.3.1 Types, Characteristics, and Applications of SAs
166(7)
5.3.2 Machinability and Machinability Rating of Super Alloys
173(1)
5.3.2.1 Machinability Aspects of Super Alloys
173(1)
5.3.2.2 Machinability Rating of Super Alloys
174(4)
5.3.3 Machining and Machining Conditions of Super Alloys
178(13)
5.4 Non-Traditional Machining of Stainless Steels and Super Alloys
191(23)
5.4.1 Machining of Stainless Steels and Super Alloys by Mechanical Techniques
192(3)
5.4.2 Machining SSs and SAs by Electrochemical and Chemical Techniques
195(12)
5.4.3 Thermoelectric Machining of Stainless Steels and Super Alloys
207(7)
5.5 Review Questions
214(2)
References
216(3)
Chapter 6 Machining of DTC Materials (Ceramics and Composites) by Traditional and Non-Traditional Methods
219(48)
6.1 Introduction
219(1)
6.2 Machining of Ceramic Materials
219(27)
6.2.1 Ceramic as a Promising Engineering Material
219(2)
6.2.2 Types, Characteristics, Classification, and Applications of Ceramics
221(1)
6.2.2.1 Types, Characteristics, and Classification
221(4)
6.2.2.2 Fields of Applications
225(1)
6.2.3 Fabrication Techniques of Crystalline Ceramics
226(1)
6.2.3.1 Processing Techniques and Shaping of Green Bodies
227(2)
6.2.3.2 Green Machining Processes of Green and Pre-Sintered Ceramics
229(1)
6.2.3.3 Hard Machining Processes of Sintered Ceramics
230(16)
6.3 Machining of Composite Materials
246(16)
6.3.1 Types, Characteristics, and Applications of Composites
246(1)
6.3.2 Traditional Machining and Machinability of Composites
247(11)
6.3.3 Non-Traditional Machining and Machinability of Composites
258(4)
6.4 Review Questions
262(1)
References
263(4)
Chapter 7 Assisted Machining Technologies
267(32)
7.1 Introduction
267(1)
7.2 Thermal-Assisted Machining
267(3)
7.2.1 Laser-Assisted Machining
268(1)
7.2.2 Plasma-Assisted Machining
269(1)
7.3 Vibration-Assisted Machining (VAM)
270(13)
7.3.1 Principles and Aims of VAM
270(4)
7.3.2 Vibration-Assisted Traditional Machining Processes
274(1)
7.3.2.1 Vibration-Assisted Turning
274(1)
7.3.2.2 Vibration-Assisted Drilling
274(1)
7.3.2.3 Vibration-Assisted Milling
275(1)
7.3.2.4 Vibration-Assisted Grinding
276(1)
7.3.3 Vibration-Assisted Non-Traditional Machining Processes
276(1)
7.3.3.1 Vibration-Assisted Electrochemical Machining (VAECM)
276(4)
7.3.3.2 Vibration-Assisted Electrodischarge Machining
280(2)
7.3.3.3 Vibration-Assisted Laser Beam Machining
282(1)
7.3.3.4 Vibration-Assisted Abrasive Water Jet Machining
282(1)
7.4 Magnetic Field-Assisted Processes
283(13)
7.4.1 Magnetic Abrasive Finishing (MAF)
284(1)
7.4.1.1 Finishing of Outer Cylindrical Surfaces and Typical Machining Conditions of MAF
285(5)
7.4.1.2 MAF Finishing of Inner Cylindrical Surfaces
290(1)
7.4.1.3 Semi-Magnetic Abrasive Finishing (SMAF)
290(1)
7.4.1.4 Other MAF Applications
291(1)
7.4.2 Magnetic Float Polishing (MFP) or Magnetic Fluid Grinding (MFG)
291(3)
7.4.3 Advantages of MFAP
294(1)
7.4.4 Magnetorheological Finishing (MRF)
294(1)
7.4.5 Magnetorheological Abrasive Flow Finishing (MRAFF)
295(1)
7.5 Review Questions
296(1)
References
296(3)
Chapter 8 Design for Machining
299(62)
8.1 Introduction
299(1)
8.1.1 General Design Rules
300(1)
8.2 General Design Recommendations
300(3)
8.3 Design for Machining by Cutting
303(34)
8.3.1 Turning
303(1)
8.3.1.1 Economic Production Quantities
304(1)
8.3.1.2 Design Recommendations for Turning
305(4)
8.3.1.3 Dimensional Control
309(2)
8.3.2 Drilling and Allied Operations
311(1)
8.3.2.1 Economic Production Quantities
312(1)
8.3.2.2 Design Recommendations for Drilling and Allied Operations
312(4)
8.3.2.3 Dimensional Control
316(1)
8.3.3 Milling
316(1)
8.3.3.1 Design Recommendations
316(3)
8.3.3.2 Dimensional Factors and Tolerances
319(2)
8.3.4 Shaping, Planing, and Slotting
321(1)
8.3.4.1 Design Recommendations
321(2)
8.3.4.2 Dimensional Control
323(1)
8.3.5 Broaching
323(1)
8.3.5.1 Design Recommendations
324(7)
8.3.5.2 Dimensional Factors
331(1)
8.3.5.3 Recommended Tolerances
331(1)
8.3.6 Thread Cutting
332(1)
8.3.6.1 Design Recommendations
332(1)
8.3.6.2 Dimensional Factors and Tolerances
333(1)
8.3.7 Gear Cutting
334(1)
8.3.7.1 Design Recommendations
334(2)
8.3.7.2 Dimensional Factors
336(1)
8.4 Design for Grinding
337(6)
8.4.1 Surface Grinding
337(1)
8.4.1.1 Design Recommendations
337(1)
8.4.1.2 Dimensional Control
338(1)
8.4.2 Cylindrical Grinding
339(1)
8.4.2.1 Design Recommendations
339(1)
8.4.2.2 Dimensional Factors
340(1)
8.4.3 Centerless Grinding
341(1)
8.4.3.1 Design Recommendations
341(2)
8.4.3.2 Dimensional Control
343(1)
8.5 Design for Abrasive Finishing Processes
343(2)
8.5.1 Honing
343(1)
8.5.2 Lapping
344(1)
8.5.3 Superfinishing
345(1)
8.6 Design for Chemical and Electrochemical Machining
345(7)
8.6.1 Chemical Machining
345(1)
8.6.1.1 Design Recommendations
345(2)
8.6.1.2 Dimensional Factors and Tolerances
347(1)
8.6.2 Electrochemical Machining
348(1)
8.6.2.1 Design Recommendations
348(3)
8.6.2.2 Dimensional Factors
351(1)
8.6.3 Electrochemical Grinding
351(1)
8.6.3.1 Design Recommendations
352(1)
8.6.3.2 Dimensional Factors
352(1)
8.7 Design for Thermal Machining
352(4)
8.7.1 Electrodischarge Machining
352(1)
8.7.1.1 Design Recommendations
352(1)
8.7.1.2 Dimensional Factors
353(1)
8.7.2 Electron Beam Machining
354(1)
8.7.3 Laser Beam Machining
355(1)
8.8 Design for Ultrasonic Machining
356(2)
8.9 Design for Abrasive Jet Machining
358(1)
8.10 Review Questions
359(1)
References
360(1)
Chapter 9 Accuracy and Surface Integrity Realized by Machining Processes
361(32)
9.1 Introduction
361(1)
9.2 Surface Texture
361(3)
9.3 Surface Quality and Functional Properties
364(1)
9.4 Surface Integrity
365(4)
9.5 Surface Effects by Traditional Machining
369(7)
9.5.1 Chip Removal Processes
369(1)
9.5.2 Grinding
369(7)
9.6 Surface Effects by Non-Traditional Machining
376(12)
9.6.1 Electrochemical and Chemical Machining
377(3)
9.6.2 Thermal Non-Traditional Processes
380(1)
9.6.2.1 Electrodischarge Machining
380(4)
9.6.2.2 Laser Beam Machining
384(2)
9.6.2.3 Electron Beam Machining
386(1)
9.6.2.4 Plasma Beam Machining (PBM)
386(1)
9.6.2.5 Electroerosion Dissolution Machining
386(1)
9.6.2.6 Electrochemical Discharge Grinding
387(1)
9.6.3 Mechanical Non-Traditional Processes
387(1)
9.7 Reducing Distortion and Surface Effects in Machining
388(2)
9.8 Review Questions
390(1)
References
390(3)
Chapter 10 Environment-Friendly Machine Tools and Operations
393(36)
10.1 Introduction
393(4)
10.2 Traditional Machining
397(13)
10.2.1 Cutting Fluids
400(1)
10.2.1.1 Classification of Cutting Fluids
400(1)
10.2.1.2 Selection of Cutting Fluids
401(1)
10.2.1.3 Evaluation of Cutting Fluids
401(2)
10.2.2 Hazard Ranking of Cutting Fluids
403(1)
10.2.3 Health Hazards of Cutting Fluids
403(2)
10.2.4 Cryogenic Cooling
405(1)
10.2.5 Ecological Machining
405(1)
10.2.6 Factors Affecting the Use of MQL
406(1)
10.2.7 Applications of Ecological Machining
407(3)
10.3 Non-Traditional Machining Processes
410(17)
10.3.1 Chemical Machining
410(3)
10.3.2 Electrochemical Machining
413(2)
10.3.3 Electrodischarge Machining
415(3)
10.3.3.1 Protective Measures
418(1)
10.3.4 Laser Beam Machining
418(3)
10.3.5 Ultrasonic Machining
421(1)
10.3.5.1 Electromagnetic Field
421(1)
10.3.5.2 Ultrasonic Waves
422(1)
10.3.5.3 Abrasives Slurry
423(1)
10.3.5.4 Contact Hazards
424(1)
10.3.5.5 Other Hazards
424(1)
10.3.6 Abrasive Jet Machining
424(3)
10.4 Review Questions
427(1)
References
428(1)
Chapter 11 Hexapods and Machining Technology
429(1)
11.1 Introduction
429(1)
11.2 Historical Background
429(3)
11.3 Hexapod Mechanism and Design Features
432(7)
11.3.1 Hexapod Mechanism
432(1)
11.3.2 Design Features
433(1)
11.3.2.1 Hexapods of Telescopic Struts (Ingersoll System)
433(3)
11.3.2.2 Hexapods of Ball Screw Struts (Hexel and Geodetic System)
436(3)
11.4 Hexapod Constructional Elements
439(10)
11.4.1 Strut Assembly
439(1)
11.4.2 Sphere Drive
440(1)
11.4.3 Bifurcated Balls
441(3)
11.4.4 Spindles
444(1)
11.4.5 Articulated Head
444(1)
11.4.6 Upper Platform
445(2)
11.4.7 Control System
447(2)
11.5 Hexapod Characteristics
449(5)
11.6 Manufacturing Applications
454(4)
11.7 Review Questions
458(1)
References
458(1)
Index 459
Preface xv
Acknowledgments xvii
Author Biographies xix
List of Symbols
xxi
List of Acronyms
xxv
Chapter 1 Machining Technology
1(14)
1.1 Introduction
1(1)
1.2 History of Machine Tools
2(4)
1.3 Basic Motions in Machine Tools
6(1)
1.4 Aspects of Machining Technology
6(7)
1.4.1 Machine Tool
10(2)
1.4.2 Workpiece Material
12(1)
1.4.3 Machining Productivity
12(1)
1.4.4 Accuracy and Surface Integrity
12(1)
1.4.5 Product Design for Economical Machining
12(1)
1.4.6 Environmental Impacts of Machining
13(1)
1.5 Review Questions
13(1)
References
13(2)
Chapter 2 Basic Elements and Mechanisms of Machine Tools
15(60)
2.1 Introduction
15(2)
2.2 Machine Tool Structures
17(7)
2.2.1 Light- and Heavy-weight Constructions
23(1)
2.3 Machine-Tool Guideways
24(6)
2.3.1 Sliding Friction Guideways
24(3)
2.3.2 Rolling Friction Guideways
27(1)
2.3.3 Externally Pressurized Guideways
28(2)
2.4 Machine-Tool Spindles
30(7)
2.4.1 Spindle Bearings
30(3)
2.4.2 Selection of Spindle-Bearing Fit
33(2)
2.4.3 Sliding Friction Spindle Bearing
35(2)
2.5 Machine Tool Drives
37(19)
2.5.1 Stepped Speed Drives
37(1)
2.5.1.1 Belting
37(1)
2.5.1.2 Pick-Off Gears
38(1)
2.5.1.3 Gearboxes
39(1)
2.5.1.4 Stepping of Speeds According to Arithmetic Progression
40(1)
2.5.1.5 Stepping of Speeds According to Geometric Progression
41(5)
2.5.1.6 Kinetic Calculations of Speed Gearboxes
46(1)
2.5.1.7 Application of Pole-Changing Induction Motors
46(2)
2.5.1.8 Feed Gearboxes
48(1)
2.5.1.9 Preselection of Feeds and Speeds
49(2)
2.5.2 Stepless Speed Drives
51(1)
2.5.2.1 Mechanical Stepless Drives
51(2)
2.5.2.2 Electrical Stepless Speed Drive
53(1)
2.5.2.3 Hydraulic Stepless Speed Drive
54(2)
2.6 Planetary Transmission
56(1)
2.7 Machine-Tool Motors
57(1)
2.8 Reversing Mechanisms
58(1)
2.9 Couplings and Brakes
59(2)
2.10 Reciprocating Mechanisms
61(3)
2.10.1 Quick-Return Mechanism
61(2)
2.10.2 Whitworth Mechanism
63(1)
2.10.3 Hydraulic Reciprocating Mechanism
63(1)
2.11 Material Selection and Heat Treatment of Machine-Tool Components
64(4)
2.11.1 Cast Iron
65(1)
2.11.2 Steels
65(3)
2.12 Testing of Machine Tools
68(3)
2.13 Maintenance of Machine Tools
71(1)
2.13.1 Preventive Maintenance
71(1)
2.13.2 Corrective Maintenance
71(1)
2.13.3 Reconditioning
72(1)
2.14 Review Questions
72(1)
References
73(2)
Chapter 3 General-Purpose Metal-Cutting Machine Tools
75(78)
3.1 Introduction
75(1)
3.2 Lathe Machines and Operations
75(13)
3.2.1 Turning Operations
75(3)
3.2.2 Metal-Cutting Lathes
78(1)
3.2.2.1 Universal Engine Lathes
79(8)
3.2.2.2 Other Types of General-Purpose Metal-Cutting Lathes
87(1)
3.3 Drilling Machines and Operations
88(17)
3.3.1 Drilling and Drilling-Allied Operations
88(1)
3.3.1.1 Drilling Operation
88(2)
3.3.1.2 Drilling-Allied Operations
90(3)
3.3.2 General-Purpose Drilling Machines
93(1)
3.3.2.1 Bench-Type Sensitive Drill Presses
93(1)
3.3.2.2 Upright Drill Presses
93(2)
3.3.2.3 Radial Drilling Machines
95(1)
3.3.2.4 Multispindle Drilling Machines
96(1)
3.3.2.5 Horizontal Drilling Machines for Drilling Deep Holes
97(1)
3.3.3 Tool-Holding Accessories of Drilling Machines
97(3)
3.3.4 Work-Holding Devices Used on Drilling Machines
100(5)
3.4 Milling Machines and Operations
105(21)
3.4.1 Milling Operations
105(1)
3.4.1.1 Peripheral Milling
106(1)
3.4.1.2 Face Milling
107(1)
3.4.2 Milling Cutters
108(2)
3.4.3 General-Purpose Milling Machines
110(1)
3.4.3.1 Knee-Type Milling Machines
110(2)
3.4.3.2 Vertical Bed-Type Milling Machines
112(1)
3.4.3.3 Planer-Type Milling Machines
112(1)
3.4.3.4 Rotary-Table Milling Machines
112(3)
3.4.4 Holding Cutters and Workpieces on Milling Machines
115(1)
3.4.4.1 Cutter Mounting
115(1)
3.4.4.2 Workpiece Fixturing
116(3)
3.4.5 Dividing Heads
119(1)
3.4.5.1 Universal Dividing Heads
120(1)
3.4.5.2 Modes of Indexing
121(5)
3.5 Shapers, Planers, and Slotters and Their Operations
126(10)
3.5.1 Shaping, Planing, and Slotting Processes
126(3)
3.5.1.1 Determination of vcm in Accordance with the Machine Mechanism
129(1)
3.5.2 Shaper and Planer Tools
130(1)
3.5.3 Shapers, Planers, and Slotters
130(1)
3.5.3.1 Shapers
130(2)
3.5.3.2 Planers
132(3)
3.5.3.3 Slotters
135(1)
3.6 Boring Machines and Operations
136(4)
3.6.1 Boring
136(1)
3.6.2 Boring Tools
137(1)
3.6.2.1 Types of Boring Tools
137(1)
3.6.2.2 Materials of Boring Tools
138(1)
3.6.3 Boring Machines
138(1)
3.6.3.1 General-Purpose Boring Machines
138(1)
3.6.3.2 Jig-Boring Machines
139(1)
3.7 Broaching Machines and Operations
140(10)
3.7.1 Broaching
140(2)
3.7.1.1 Advantages and Limitations of Broaching
142(1)
3.7.2 The Broach Tool
143(1)
3.7.2.1 Tool Geometry and Configuration
143(3)
3.7.2.2 Broach Material
146(1)
3.7.2.3 Broach Sharpening
146(1)
3.7.3 Broaching Machines
147(1)
3.7.3.1 Horizontal Broaching Machines
148(1)
3.7.3.2 Vertical Broaching Machines
148(1)
3.7.3.3 Continuous Horizontal Surface Broaching Machines
149(1)
3.8 Review Questions
150(2)
References
152(1)
Chapter 4 General-Purpose Abrasive Machine Tools
153(42)
4.1 Grinding Machines and Operations
153(25)
4.1.1 Grinding Process
153(2)
4.1.2 Grinding Wheels
155(1)
4.1.2.1 Manufacturing Characteristics of Grinding Wheels
156(5)
4.1.2.2 Grinding Wheel Geometry
161(1)
4.1.2.3 Mounting and Balancing of Grinding Wheels and Safety Measures
161(4)
4.1.2.4 Truing and Dressing of Grinding Wheels
165(2)
4.1.3 Grinding Machines
167(1)
4.1.3.1 Surface-Grinding Machines and Related Operations
167(1)
4.1.3.2 External Cylindrical Grinding Machines and Related Operations
168(4)
4.1.3.3 Internal Grinding Machines and Related Operations
172(1)
4.1.3.4 Centerless Grinding Machines and Related Operations
173(5)
4.2 Microfinishing Machines and Operations
178(16)
4.2.1 Honing
179(2)
4.2.1.1 Process Capabilities
181(1)
4.2.1.2 Machining Parameters
182(1)
4.2.1.3 Honing Machines
183(1)
4.2.2 Superfinishing (Microhoning)
184(1)
4.2.2.1 Machining Parameters
184(1)
4.2.3 Lapping
185(1)
4.2.3.1 Machining Parameters
186(1)
4.2.3.2 Lapping Machines
186(8)
4.3 Review Questions
194(1)
References
194(1)
Chapter 5 Thread-Cutting Machines and Operations
195(30)
5.1 Introduction
195(2)
5.2 Thread Cutting
197(21)
5.2.1 Cutting Threads on the Lathe
199(3)
5.2.2 Thread Chasing
202(1)
5.2.3 Thread Tapping
203(6)
5.2.4 Die Threading
209(1)
5.2.4.1 Die-Threading Machines
209(4)
5.2.4.2 Die-Threading Performance
213(2)
5.2.5 Thread Milling
215(1)
5.2.5.1 Thread-Milling Machines
216(1)
5.2.6 Thread Broaching
217(1)
5.3 Thread Grinding
218(4)
5.3.1 Center-Type Thread Grinding
218(1)
5.3.2 Centerless Thread Grinding
219(3)
5.4 Review Questions
222(1)
References
222(3)
Chapter 6 Gear-Cutting Machines and Operations
225(40)
6.1 Introduction
225(2)
6.2 Forming and Generating Methods in Gear Cutting
227(27)
6.2.1 Gear Cutting by Forming
227(1)
6.2.1.1 Gear Milling
228(5)
6.2.1.2 Gear Broaching
233(1)
6.2.1.3 Gear Forming by a Multiple-Tool Shaping Head
233(1)
6.2.1.4 Straight Bevel Gear Forming Methods
234(1)
6.2.2 Gear Cutting by Generation
235(1)
6.2.2.1 GearHobbing
235(8)
6.2.2.2 Gear Shaping with Pinion Cutter
243(3)
6.2.2.3 Gear Shaping with Rack Cutter
246(2)
6.2.2.4 Cutting Straight Bevel Gears by Generation
248(6)
6.3 Selection of Gear-Cutting Method
254(1)
6.4 Gear Finishing Operations
254(9)
6.4.1 Finishing Gears Prior to Hardening
256(1)
6.4.1.1 Gear Shaving
256(2)
6.4.1.2 Gear Burnishing
258(1)
6.4.2 Finishing Gears after Hardening
259(1)
6.4.2.1 Gear Grinding
259(3)
6.4.3 Gear Lapping
262(1)
6.5 Review Questions and Problems
263(1)
References
264(1)
Chapter 7 Turret and Capstan Lathes
265(20)
7.1 Introduction
265(1)
7.2 Difference between Capstan and Turret Lathes
265(2)
7.3 Selection and Application of Capstan and Turret Lathes
267(1)
7.4 Principal Elements of Capstan and Turret Lathes
268(4)
7.4.1 Headstock and Spindle Assembly
268(2)
7.4.2 Carriage/Cross-Slide Unit
270(1)
7.4.3 Hexagonal Turret
270(1)
7.4.3.1 Manually Controlled Machines
271(1)
7.4.3.2 Automatically Controlled Headstock Turret Lathes
272(1)
7.4.4 Cross-Sliding Hexagonal Turret
272(1)
7.5 Turret Tooling Setups
272(10)
7.5.1 Job Analysis
272(4)
7.5.2 Tooling Layout
276(6)
7.6 Review Questions
282(1)
References
283(2)
Chapter 8 Automated Lathes
285(60)
8.1 Introduction
285(1)
8.2 Degree of Automation and Production Capacity
286(2)
8.3 Classification of Automated Lathes
288(2)
8.4 Semiautomatic Lathes
290(5)
8.4.1 Single-Spindle Semiautomatics
290(2)
8.4.2 Multispindle Semiautomatics
292(3)
8.5 Fully Automatic Lathes
295(28)
8.5.1 Single-Spindle Automatic
295(1)
8.5.1.1 Turret Automatic Screw Machine
295(12)
8.5.1.2 Swiss-Type Automatic
307(5)
8.5.2 Horizontal Multispindle Bar and Chucking Automatics
312(1)
8.5.2.1 Special Features of Multispindle Automatics
312(2)
8.5.2.2 Characteristics of Parallel- and Progressive-Action Multispindle Automatic
314(3)
8.5.2.3 Operation Principles and Constructional Features of a Progressive Multispindle Automatic
317(6)
8.6 Design and Layout of Cams for Fully Automatics
323(20)
8.6.1 Tooling Layout and Establishing a Sequence of Operation
324(2)
8.6.2 Cam Design
326(3)
8.6.3 Illustrative Examples on Cam Design and Tooling Layout for Single- and Multi-Spindle Automatics
329(14)
8.7 Review Questions and Problems
343(1)
References
344(1)
Chapter 9 Numerical Control and Computer Numerical Control
345(70)
9.1 Introduction
345(5)
9.2 Coordinate System
350(5)
9.2.1 Machine-Tool Axes for NC
350(1)
9.2.2 Quadrant Notation
350(2)
9.2.3 Point Location
352(1)
9.2.4 Zero Point Location
353(1)
9.2.5 Setup Point
354(1)
9.2.6 Absolute and Incremental Positioning
355(1)
9.3 Machine Movements in Numerical Control Systems
355(3)
9.4 Interpolation
358(1)
9.5 Control of Numerical Control Machine Tools
358(2)
9.6 Components of Numerical Control Machine Tools
360(4)
9.7 Tooling for Numerical Control Machines
364(3)
9.8 Types of Numerical Control Machine Tools
367(4)
9.9 Input Units
371(2)
9.10 Forms of Numerical Control Instructions
373(1)
9.11 Program Format
374(1)
9.12 Feed and Spindle Speed Coding
375(4)
9.12.1 Feed Rate Coding
375(3)
9.12.2 Spindle Speed Coding
378(1)
9.13 Features of Numerical Control Systems
379(3)
9.14 Part Programming
382(4)
9.15 Programming Machining Centers
386(9)
9.15.1 Planning the Program
386(4)
9.15.2 Canned Cycles
390(5)
9.16 Programming Turning Centers
395(7)
9.16.1 Planning the Program
395(2)
9.16.2 Canned Turning Cycles
397(5)
9.17 Computer-Assisted Part Programming
402(5)
9.17.1 Automatically Programmed Tools Language
402(3)
9.17.2 Programming Stages
405(2)
9.18 CAD/CAM Approach to Part Programming
407(3)
9.18.1 Computer-Aided Design
407(1)
9.18.2 Computer-Aided Manufacturing
408(1)
9.18.2.1 Postprocessor
409(1)
9.18.2.2 Simulation
409(1)
9.18.2.3 Download the CNC Programs
410(1)
9.19 Review Questions
410(3)
References
413(2)
Chapter 10 Automated Manufacturing Systems
415(30)
10.1 Introduction
415(2)
10.2 Manufacturing Systems
417(5)
10.3 Flexible Automation-Flexible Manufacturing Systems
422(3)
10.3.1 Elements of Flexible Manufacturing System
423(1)
10.3.2 Limitations of Flexible Manufacturing System
424(1)
10.3.3 Features and Characteristics
424(1)
10.3.4 New Developments in Flexible Manufacturing System Technology
425(1)
10.4 Computer-Integrated Manufacturing
425(7)
10.4.1 Computer-Aided Design
430(1)
10.4.2 Computer-Aided Process Planning
430(2)
10.4.3 Computer-Aided Manufacturing
432(1)
10.5 Lean Production---Just-in-Time Manufacturing Systems
432(3)
10.5.1 Steps for Implementing the IMPS Lean Production
433(1)
10.5.2 Just-in-Time and Just-in-Case Production
434(1)
Advantages of Just-in-Time
435(1)
10.6 Adaptive Control
436(2)
10.6.1 Integration of AC into CAD/CAM/CIM Systems
438(1)
10.7 Smart Manufacturing and Artificial Intelligence
438(3)
10.7.1 Expert Systems
438(1)
10.7.2 Machine Vision
439(1)
10.7.3 Artificial Neural Networks
439(1)
10.7.4 Natural-Language Systems
440(1)
10.7.5 Fuzzy Logic (Fuzzy Models)
440(1)
10.8 Factory of the Future
441(1)
10.9 Concluding Remarks Related to Automated Manufacturing
441(1)
10.10 Review Questions
442(1)
References
443(2)
Chapter 11 Machine-Tool Dynamometers
445(24)
11.1 Introduction
445(1)
11.2 Design Features and Requirements
445(3)
11.2.1 Rapier Parameters for Dynamometer Design
446(2)
11.2.2 Main Requirements of a Good Dynamometer
448(1)
11.3 Dynamometers Based On Displacement Measurements
448(1)
11.3.1 Two-Channel Cantilever (Chisholm) Dynamometer
448(1)
11.3.2 Two-Channel Slotted Cantilever Dynamometer
449(1)
11.4 Dynamometers Based on Strain Measurement
449(12)
11.4.1 Strain Gauges and Wheatstone Bridges
450(3)
11.4.2 Cantilever Strain Gauge Dynamometers
453(1)
11.4.3 Octagonal Ring Dynamometers
454(1)
11.4.3.1 Strain Rings and Octagonal Ring Transducers
454(5)
11.4.3.2 Turning Dynamometer
459(1)
11.4.3.3 Surface Plunge-Cut Grinding Dynamometer
459(1)
11.4.3.4 Milling Dynamometers
460(1)
11.5 Piezoelectric (Quartz) Dynamometers
461(5)
11.5.1 Principles and Features
461(3)
11.5.2 Typical Piezoelectric Dynamometers
464(2)
11.6 Review Questions
466(1)
References
467(2)
Index 469
Professor Hassan El-Hofy received his BSc in production engineering from Alexandria University (Egypt) in 1976 and served as a teaching assistant in the same department. He then received his MSc in production engineering from Alexandria University in 1979. Professor El-Hofy has had a successful career in education, training, and research. Following his MSc, he worked as an assistant lecturer until October 1980 when he left for Aberdeen University in Scotland and began his PhD work with Professor J. McGeough in hybrid machining processes. He won the Overseas Research Student (ORS) Award during the course of his doctoral degree, which he duly completed in 1985. He then returned to Alexandria University and resumed work as an assistant professor. In 1990, he was promoted to an associate professor. He was on sabbatical as a visiting professor at Al-Fateh University in Tripoli between 1989 and 1994.

Professor El-Hofy wrote his first book entitled Advanced Machining Processes: Nontraditional and Hybrid Processes, which was published by McGraw Hill Co in 2005. His second book entitled Fundamentals of Machining ProcessesConventional and Nonconventional Processes appeared in September 2007 and was published by Taylor & Francis Group, CRC Press. He also coauthored a book entitled Machining TechnologyMachine Tools and Operations, which was published by Taylor & Francis Group, CRC Press in 2008. In 2011, he released his fourth book entitled Manufacturing TechnologyMaterials, Processes, and Equipment, which again was published by Taylor & Francis Group, CRC Press. Professor El-Hofy has published over 80 scientific and technical papers and has supervised many graduate students in the area of machining by nontraditional methods. He serves as a consulting editor to many international journals and is a regular participant in international conferences. Between August, 2007, and August 2010 he was the chairman of the Department of Production Engineering, College of Engineering of Alexandria University where he was teaching several machining and related technology courses. In October 2011 he was nominated as the vice dean for education and student's affairs at the college of Engineering, Alexandria University. Between December 2012 and February 2018 he was the Dean of the Innovative Design Engineering School at Egypt-Japan University of Science and Technology (E-JUST) in Alexandria, Egypt. He worked as the acting vice president of research from December 2014 to April 2017 at E-JUST. Currently he is the professor of machining technology at the Department of Industrial and manufacturing Engineering at E-JUST.

Professor Helmi A. A. Youssef, born in August, 1938 in Alexandria, Egypt, has acquired his B.Sc. degree with honor in Production Engineering from Alexandria University in 1960. He completed then his scientific building in the Carolo-Welhelmina, TH Braunschweig in Germany during the period 1961-1967. In June 1964 he acquired his Dipl.-Ing. degree, then in December 1967, he completed his Dr.-Ing. degree in the domain of Non-traditional Machining. In 1968, he has returned to Alexandria University, Production Engineering Dept. as an assistant professor. In 1973 he has been promoted to associate, and in 1978 to full professor. In the period 1995-1998, professor Youssef was the chairman of the Production Engineering Dept., Alexandria University. Since 1989, he is a member of the scientific committee for promotion of professors in Egyptian universities.

Based on several research and educational laboratories, which he has built, Professor Youssef founded his own scientific school in both Traditional and Non-traditional Machining Technologies. Professor Youssef has organized and participated in many international conferences. He has published many scientific papers in specialized journals. He authored many books in his fields of specialization. Currently, he is an emeritus professor in PED, Alexandria University.