Preface |
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xv | |
Acknowledgements |
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xvii | |
Author Biographies |
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xix | |
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xxi | |
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xxiii | |
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UNIT I Non-Traditional Machining Operations and Non-Traditional Machine Tools |
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Chapter 1 Non-Traditional Machining Processes |
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3 | (4) |
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3 | (1) |
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1.2 Classification of Non-Traditional Machining Processes |
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4 | (1) |
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5 | (1) |
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6 | (1) |
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Chapter 2 Mechanical Non-Traditional Machining Operations and Machine Tools |
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7 | (56) |
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2.1 Jet Machines and Operations |
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7 | (21) |
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2.1.1 Abrasive Jet Machining |
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7 | (1) |
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2.1.1.1 Process Characteristics and Applications |
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7 | (2) |
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2.1.1.2 Work Station of Abrasive Jet Machining |
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9 | (1) |
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2.1.1.3 Process Capabilities |
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10 | (1) |
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2.1.2 Water Jet Machining (Hydrodynamic Machining) |
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11 | (1) |
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2.1.2.1 Process Characteristics and Applications |
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11 | (3) |
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14 | (3) |
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2.1.2.3 Process Capabilities |
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17 | (1) |
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2.1.3 Abrasive Water Jet Machining |
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17 | (1) |
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2.1.3.1 Process Characteristics and Applications |
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17 | (4) |
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21 | (5) |
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2.1.3.3 Process Capabilities |
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26 | (2) |
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28 | (26) |
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2.2.1 Definition, Characteristics, and Applications |
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28 | (3) |
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31 | (5) |
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2.2.3 Design of Acoustic Horns |
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36 | (14) |
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2.2.4 Process Capabilities |
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50 | (3) |
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2.2.5 Recent Developments |
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53 | (1) |
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2.3 Abrasive Flow Machining |
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54 | (6) |
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54 | (1) |
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2.3.2 Process Parameters of Abrasive Flow Machining |
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55 | (5) |
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2.3.3 Applications of AFM |
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60 | (1) |
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2.4 Review Questions and Problems |
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60 | (1) |
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61 | (2) |
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Chapter 3 Chemical and Electrochemical Non-Traditional Machining Operations and Machine Tools |
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63 | (36) |
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63 | (11) |
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63 | (7) |
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3.1.2 Photochemical Machining (Spray Etching) |
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70 | (4) |
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3.2 Electrochemical Machines and Operations |
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74 | (21) |
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3.2.1 Process Characteristics and Applications |
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74 | (3) |
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77 | (3) |
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3.2.3 ECM Equipment (EC Sinking Machine) |
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80 | (2) |
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3.2.4 Process Capabilities |
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82 | (1) |
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3.2.5 ECM Allied Processes |
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82 | (1) |
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3.2.5.1 Shaped Tube Electrolytic Machining |
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82 | (3) |
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3.2.5.2 Electrostream (Capillary) Drilling |
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85 | (2) |
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3.2.5.3 Electrochemical Jet Drilling |
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87 | (1) |
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3.2.5.4 Electrochemical Deburring |
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87 | (3) |
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3.2.5.5 Electrochemical Polishing |
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90 | (1) |
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3.2.5.6 Electrochemical Sharpening |
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91 | (1) |
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3.2.5.7 Electrochemical Grinding |
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92 | (2) |
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3.2.5.8 Electrochemical Honing |
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94 | (1) |
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3.3 Review Questions and Problems |
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95 | (2) |
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97 | (2) |
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Chapter 4 Thermo-Electrical Non-Traditional Machining Operations and Machine Tools |
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99 | (48) |
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4.1 Electrical Discharge Machines and Operations |
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99 | (17) |
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4.1.1 Process Characteristics and Applications |
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99 | (3) |
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102 | (3) |
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4.1.3 EDM-Spark Circuits (Power Supply Circuits) |
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105 | (1) |
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4.1.3.1 Resistance-Capacitance RC Circuit |
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105 | (3) |
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4.1.3.2 Transistorized Pulse Generator Circuits |
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108 | (1) |
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4.1.4 EDM Tool Electrodes |
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109 | (1) |
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4.1.5 Process Capabilities |
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110 | (2) |
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4.1.6 EDM Allied Processes |
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112 | (1) |
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4.1.6.1 Electrical Discharge Milling (ED Milling) |
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112 | (3) |
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4.1.6.2 Electrical Discharge Wire Cutting |
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115 | (1) |
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4.2 Electron Beam Machining Equipment and Operations |
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116 | (7) |
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4.2.1 Process Characteristics and Applications |
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116 | (2) |
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4.2.2 Electron Beam Machining Equipment |
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118 | (2) |
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4.2.3 Process Capabilities |
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120 | (3) |
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4.3 Laser Beam Machining Equipment and Operations |
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123 | (12) |
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4.3.1 Process Characteristics |
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123 | (2) |
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125 | (1) |
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4.3.2.1 Pyrolithic and Photolithic Lasers |
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125 | (1) |
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4.3.2.2 Industrial Lasers |
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125 | (2) |
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4.3.3 Laser Beam Machining Operations |
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127 | (4) |
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131 | (1) |
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4.3.5 Applications and Capabilities |
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132 | (3) |
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4.4 Plasma Arc Cutting Systems and Operations |
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135 | (4) |
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4.4.1 Process Characteristics |
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135 | (1) |
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4.4.2 Plasma Arc Cutting Systems |
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136 | (1) |
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4.4.3 Applications and Capabilities of PAC |
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137 | (2) |
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4.5 Review Questions and Problems |
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139 | (4) |
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143 | (4) |
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UNIT II Advanced Machining Technology |
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Chapter 5 Machining of DTC Materials (Stainless Steels and Super Alloys) by Traditional and Non-Traditional Methods |
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147 | (72) |
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147 | (1) |
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5.2 Traditional Machining of Stainless Steels |
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147 | (19) |
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5.2.1 Types, Characteristics, and Applications of SSs |
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147 | (5) |
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5.2.2 Machinability and Machinability Ratings of SSs |
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152 | (1) |
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5.2.2.1 Free-Machining Additives of Stainless Steels |
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152 | (1) |
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5.2.2.2 Machinability of Free- and Non-Free-Machining Stainless Steels |
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153 | (2) |
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5.2.2.3 Enhanced Machining Stainless Steels |
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155 | (1) |
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5.2.2.4 Machinability Ratings of Stainless Steels |
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155 | (1) |
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5.2.3 Machining and Machining Conditions of SSs |
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156 | (10) |
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5.3 Traditional Machining of Super Alloys |
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166 | (25) |
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5.3.1 Types, Characteristics, and Applications of SAs |
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166 | (7) |
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5.3.2 Machinability and Machinability Rating of Super Alloys |
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173 | (1) |
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5.3.2.1 Machinability Aspects of Super Alloys |
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173 | (1) |
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5.3.2.2 Machinability Rating of Super Alloys |
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174 | (4) |
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5.3.3 Machining and Machining Conditions of Super Alloys |
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178 | (13) |
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5.4 Non-Traditional Machining of Stainless Steels and Super Alloys |
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191 | (23) |
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5.4.1 Machining of Stainless Steels and Super Alloys by Mechanical Techniques |
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192 | (3) |
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5.4.2 Machining SSs and SAs by Electrochemical and Chemical Techniques |
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195 | (12) |
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5.4.3 Thermoelectric Machining of Stainless Steels and Super Alloys |
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207 | (7) |
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214 | (2) |
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216 | (3) |
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Chapter 6 Machining of DTC Materials (Ceramics and Composites) by Traditional and Non-Traditional Methods |
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219 | (48) |
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219 | (1) |
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6.2 Machining of Ceramic Materials |
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219 | (27) |
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6.2.1 Ceramic as a Promising Engineering Material |
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219 | (2) |
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6.2.2 Types, Characteristics, Classification, and Applications of Ceramics |
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221 | (1) |
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6.2.2.1 Types, Characteristics, and Classification |
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221 | (4) |
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6.2.2.2 Fields of Applications |
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225 | (1) |
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6.2.3 Fabrication Techniques of Crystalline Ceramics |
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226 | (1) |
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6.2.3.1 Processing Techniques and Shaping of Green Bodies |
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227 | (2) |
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6.2.3.2 Green Machining Processes of Green and Pre-Sintered Ceramics |
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229 | (1) |
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6.2.3.3 Hard Machining Processes of Sintered Ceramics |
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230 | (16) |
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6.3 Machining of Composite Materials |
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246 | (16) |
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6.3.1 Types, Characteristics, and Applications of Composites |
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246 | (1) |
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6.3.2 Traditional Machining and Machinability of Composites |
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247 | (11) |
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6.3.3 Non-Traditional Machining and Machinability of Composites |
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258 | (4) |
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262 | (1) |
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263 | (4) |
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Chapter 7 Assisted Machining Technologies |
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267 | (32) |
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267 | (1) |
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7.2 Thermal-Assisted Machining |
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267 | (3) |
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7.2.1 Laser-Assisted Machining |
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268 | (1) |
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7.2.2 Plasma-Assisted Machining |
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269 | (1) |
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7.3 Vibration-Assisted Machining (VAM) |
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270 | (13) |
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7.3.1 Principles and Aims of VAM |
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270 | (4) |
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7.3.2 Vibration-Assisted Traditional Machining Processes |
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274 | (1) |
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7.3.2.1 Vibration-Assisted Turning |
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274 | (1) |
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7.3.2.2 Vibration-Assisted Drilling |
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274 | (1) |
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7.3.2.3 Vibration-Assisted Milling |
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275 | (1) |
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7.3.2.4 Vibration-Assisted Grinding |
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276 | (1) |
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7.3.3 Vibration-Assisted Non-Traditional Machining Processes |
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276 | (1) |
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7.3.3.1 Vibration-Assisted Electrochemical Machining (VAECM) |
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276 | (4) |
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7.3.3.2 Vibration-Assisted Electrodischarge Machining |
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280 | (2) |
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7.3.3.3 Vibration-Assisted Laser Beam Machining |
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282 | (1) |
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7.3.3.4 Vibration-Assisted Abrasive Water Jet Machining |
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282 | (1) |
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7.4 Magnetic Field-Assisted Processes |
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283 | (13) |
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7.4.1 Magnetic Abrasive Finishing (MAF) |
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284 | (1) |
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7.4.1.1 Finishing of Outer Cylindrical Surfaces and Typical Machining Conditions of MAF |
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285 | (5) |
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7.4.1.2 MAF Finishing of Inner Cylindrical Surfaces |
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290 | (1) |
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7.4.1.3 Semi-Magnetic Abrasive Finishing (SMAF) |
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290 | (1) |
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7.4.1.4 Other MAF Applications |
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291 | (1) |
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7.4.2 Magnetic Float Polishing (MFP) or Magnetic Fluid Grinding (MFG) |
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291 | (3) |
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294 | (1) |
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7.4.4 Magnetorheological Finishing (MRF) |
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294 | (1) |
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7.4.5 Magnetorheological Abrasive Flow Finishing (MRAFF) |
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295 | (1) |
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296 | (1) |
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296 | (3) |
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Chapter 8 Design for Machining |
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299 | (62) |
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299 | (1) |
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8.1.1 General Design Rules |
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300 | (1) |
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8.2 General Design Recommendations |
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300 | (3) |
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8.3 Design for Machining by Cutting |
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303 | (34) |
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303 | (1) |
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8.3.1.1 Economic Production Quantities |
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304 | (1) |
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8.3.1.2 Design Recommendations for Turning |
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305 | (4) |
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8.3.1.3 Dimensional Control |
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309 | (2) |
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8.3.2 Drilling and Allied Operations |
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311 | (1) |
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8.3.2.1 Economic Production Quantities |
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312 | (1) |
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8.3.2.2 Design Recommendations for Drilling and Allied Operations |
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312 | (4) |
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8.3.2.3 Dimensional Control |
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316 | (1) |
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316 | (1) |
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8.3.3.1 Design Recommendations |
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316 | (3) |
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8.3.3.2 Dimensional Factors and Tolerances |
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319 | (2) |
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8.3.4 Shaping, Planing, and Slotting |
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321 | (1) |
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8.3.4.1 Design Recommendations |
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321 | (2) |
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8.3.4.2 Dimensional Control |
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323 | (1) |
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323 | (1) |
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8.3.5.1 Design Recommendations |
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324 | (7) |
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8.3.5.2 Dimensional Factors |
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331 | (1) |
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8.3.5.3 Recommended Tolerances |
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331 | (1) |
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332 | (1) |
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8.3.6.1 Design Recommendations |
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332 | (1) |
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8.3.6.2 Dimensional Factors and Tolerances |
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333 | (1) |
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334 | (1) |
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8.3.7.1 Design Recommendations |
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334 | (2) |
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8.3.7.2 Dimensional Factors |
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336 | (1) |
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337 | (6) |
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337 | (1) |
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8.4.1.1 Design Recommendations |
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337 | (1) |
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8.4.1.2 Dimensional Control |
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338 | (1) |
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8.4.2 Cylindrical Grinding |
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339 | (1) |
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8.4.2.1 Design Recommendations |
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339 | (1) |
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8.4.2.2 Dimensional Factors |
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340 | (1) |
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8.4.3 Centerless Grinding |
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341 | (1) |
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8.4.3.1 Design Recommendations |
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341 | (2) |
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8.4.3.2 Dimensional Control |
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343 | (1) |
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8.5 Design for Abrasive Finishing Processes |
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343 | (2) |
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343 | (1) |
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344 | (1) |
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345 | (1) |
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8.6 Design for Chemical and Electrochemical Machining |
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345 | (7) |
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345 | (1) |
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8.6.1.1 Design Recommendations |
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345 | (2) |
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8.6.1.2 Dimensional Factors and Tolerances |
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347 | (1) |
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8.6.2 Electrochemical Machining |
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348 | (1) |
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8.6.2.1 Design Recommendations |
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348 | (3) |
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8.6.2.2 Dimensional Factors |
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351 | (1) |
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8.6.3 Electrochemical Grinding |
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351 | (1) |
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8.6.3.1 Design Recommendations |
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352 | (1) |
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8.6.3.2 Dimensional Factors |
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352 | (1) |
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8.7 Design for Thermal Machining |
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352 | (4) |
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8.7.1 Electrodischarge Machining |
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352 | (1) |
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8.7.1.1 Design Recommendations |
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352 | (1) |
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8.7.1.2 Dimensional Factors |
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353 | (1) |
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8.7.2 Electron Beam Machining |
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354 | (1) |
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8.7.3 Laser Beam Machining |
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355 | (1) |
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8.8 Design for Ultrasonic Machining |
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356 | (2) |
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8.9 Design for Abrasive Jet Machining |
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358 | (1) |
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359 | (1) |
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360 | (1) |
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Chapter 9 Accuracy and Surface Integrity Realized by Machining Processes |
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361 | (32) |
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361 | (1) |
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361 | (3) |
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9.3 Surface Quality and Functional Properties |
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364 | (1) |
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365 | (4) |
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9.5 Surface Effects by Traditional Machining |
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369 | (7) |
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9.5.1 Chip Removal Processes |
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369 | (1) |
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369 | (7) |
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9.6 Surface Effects by Non-Traditional Machining |
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376 | (12) |
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9.6.1 Electrochemical and Chemical Machining |
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377 | (3) |
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9.6.2 Thermal Non-Traditional Processes |
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380 | (1) |
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9.6.2.1 Electrodischarge Machining |
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380 | (4) |
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9.6.2.2 Laser Beam Machining |
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384 | (2) |
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9.6.2.3 Electron Beam Machining |
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386 | (1) |
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9.6.2.4 Plasma Beam Machining (PBM) |
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386 | (1) |
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9.6.2.5 Electroerosion Dissolution Machining |
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386 | (1) |
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9.6.2.6 Electrochemical Discharge Grinding |
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387 | (1) |
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9.6.3 Mechanical Non-Traditional Processes |
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387 | (1) |
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9.7 Reducing Distortion and Surface Effects in Machining |
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388 | (2) |
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390 | (1) |
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390 | (3) |
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Chapter 10 Environment-Friendly Machine Tools and Operations |
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393 | (36) |
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393 | (4) |
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10.2 Traditional Machining |
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397 | (13) |
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400 | (1) |
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10.2.1.1 Classification of Cutting Fluids |
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400 | (1) |
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10.2.1.2 Selection of Cutting Fluids |
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401 | (1) |
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10.2.1.3 Evaluation of Cutting Fluids |
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401 | (2) |
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10.2.2 Hazard Ranking of Cutting Fluids |
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403 | (1) |
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10.2.3 Health Hazards of Cutting Fluids |
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403 | (2) |
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405 | (1) |
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10.2.5 Ecological Machining |
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405 | (1) |
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10.2.6 Factors Affecting the Use of MQL |
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406 | (1) |
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10.2.7 Applications of Ecological Machining |
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407 | (3) |
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10.3 Non-Traditional Machining Processes |
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410 | (17) |
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10.3.1 Chemical Machining |
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410 | (3) |
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10.3.2 Electrochemical Machining |
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413 | (2) |
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10.3.3 Electrodischarge Machining |
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415 | (3) |
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10.3.3.1 Protective Measures |
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418 | (1) |
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10.3.4 Laser Beam Machining |
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418 | (3) |
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10.3.5 Ultrasonic Machining |
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421 | (1) |
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10.3.5.1 Electromagnetic Field |
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421 | (1) |
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10.3.5.2 Ultrasonic Waves |
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422 | (1) |
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10.3.5.3 Abrasives Slurry |
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423 | (1) |
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424 | (1) |
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424 | (1) |
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10.3.6 Abrasive Jet Machining |
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424 | (3) |
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427 | (1) |
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428 | (1) |
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Chapter 11 Hexapods and Machining Technology |
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429 | (1) |
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429 | (1) |
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11.2 Historical Background |
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429 | (3) |
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11.3 Hexapod Mechanism and Design Features |
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432 | (7) |
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432 | (1) |
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433 | (1) |
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11.3.2.1 Hexapods of Telescopic Struts (Ingersoll System) |
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433 | (3) |
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11.3.2.2 Hexapods of Ball Screw Struts (Hexel and Geodetic System) |
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436 | (3) |
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11.4 Hexapod Constructional Elements |
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439 | (10) |
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439 | (1) |
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440 | (1) |
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441 | (3) |
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444 | (1) |
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444 | (1) |
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445 | (2) |
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447 | (2) |
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11.5 Hexapod Characteristics |
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449 | (5) |
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11.6 Manufacturing Applications |
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454 | (4) |
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458 | (1) |
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|
458 | (1) |
Index |
|
459 | |
Preface |
|
xv | |
Acknowledgments |
|
xvii | |
Author Biographies |
|
xix | |
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|
xxi | |
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|
xxv | |
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Chapter 1 Machining Technology |
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1 | (14) |
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1 | (1) |
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1.2 History of Machine Tools |
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2 | (4) |
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1.3 Basic Motions in Machine Tools |
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6 | (1) |
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1.4 Aspects of Machining Technology |
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|
6 | (7) |
|
|
10 | (2) |
|
|
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) |
|
|
13 | (1) |
|
|
13 | (2) |
|
Chapter 2 Basic Elements and Mechanisms of Machine Tools |
|
|
15 | (60) |
|
|
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) |
|
|
30 | (3) |
|
2.4.2 Selection of Spindle-Bearing Fit |
|
|
33 | (2) |
|
2.4.3 Sliding Friction Spindle Bearing |
|
|
35 | (2) |
|
|
37 | (19) |
|
2.5.1 Stepped Speed Drives |
|
|
37 | (1) |
|
|
37 | (1) |
|
|
38 | (1) |
|
|
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) |
|
|
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) |
|
|
57 | (1) |
|
|
58 | (1) |
|
|
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) |
|
|
65 | (1) |
|
|
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) |
|
|
72 | (1) |
|
|
72 | (1) |
|
|
73 | (2) |
|
Chapter 3 General-Purpose Metal-Cutting Machine Tools |
|
|
75 | (78) |
|
|
75 | (1) |
|
3.2 Lathe Machines and Operations |
|
|
75 | (13) |
|
|
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) |
|
|
105 | (1) |
|
3.4.1.1 Peripheral Milling |
|
|
106 | (1) |
|
|
107 | (1) |
|
|
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) |
|
|
115 | (1) |
|
3.4.4.2 Workpiece Fixturing |
|
|
116 | (3) |
|
|
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) |
|
|
130 | (2) |
|
|
132 | (3) |
|
|
135 | (1) |
|
3.6 Boring Machines and Operations |
|
|
136 | (4) |
|
|
136 | (1) |
|
|
137 | (1) |
|
3.6.2.1 Types of Boring Tools |
|
|
137 | (1) |
|
3.6.2.2 Materials of Boring Tools |
|
|
138 | (1) |
|
|
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) |
|
|
140 | (2) |
|
3.7.1.1 Advantages and Limitations of Broaching |
|
|
142 | (1) |
|
|
143 | (1) |
|
3.7.2.1 Tool Geometry and Configuration |
|
|
143 | (3) |
|
|
146 | (1) |
|
3.7.2.3 Broach Sharpening |
|
|
146 | (1) |
|
|
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) |
|
|
150 | (2) |
|
|
152 | (1) |
|
Chapter 4 General-Purpose Abrasive Machine Tools |
|
|
153 | (42) |
|
4.1 Grinding Machines and Operations |
|
|
153 | (25) |
|
|
153 | (2) |
|
|
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) |
|
|
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) |
|
|
179 | (2) |
|
4.2.1.1 Process Capabilities |
|
|
181 | (1) |
|
4.2.1.2 Machining Parameters |
|
|
182 | (1) |
|
|
183 | (1) |
|
4.2.2 Superfinishing (Microhoning) |
|
|
184 | (1) |
|
4.2.2.1 Machining Parameters |
|
|
184 | (1) |
|
|
185 | (1) |
|
4.2.3.1 Machining Parameters |
|
|
186 | (1) |
|
|
186 | (8) |
|
|
194 | (1) |
|
|
194 | (1) |
|
Chapter 5 Thread-Cutting Machines and Operations |
|
|
195 | (30) |
|
|
195 | (2) |
|
|
197 | (21) |
|
5.2.1 Cutting Threads on the Lathe |
|
|
199 | (3) |
|
|
202 | (1) |
|
|
203 | (6) |
|
|
209 | (1) |
|
5.2.4.1 Die-Threading Machines |
|
|
209 | (4) |
|
5.2.4.2 Die-Threading Performance |
|
|
213 | (2) |
|
|
215 | (1) |
|
5.2.5.1 Thread-Milling Machines |
|
|
216 | (1) |
|
|
217 | (1) |
|
|
218 | (4) |
|
5.3.1 Center-Type Thread Grinding |
|
|
218 | (1) |
|
5.3.2 Centerless Thread Grinding |
|
|
219 | (3) |
|
|
222 | (1) |
|
|
222 | (3) |
|
Chapter 6 Gear-Cutting Machines and Operations |
|
|
225 | (40) |
|
|
225 | (2) |
|
6.2 Forming and Generating Methods in Gear Cutting |
|
|
227 | (27) |
|
6.2.1 Gear Cutting by Forming |
|
|
227 | (1) |
|
|
228 | (5) |
|
|
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) |
|
|
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) |
|
|
256 | (2) |
|
|
258 | (1) |
|
6.4.2 Finishing Gears after Hardening |
|
|
259 | (1) |
|
|
259 | (3) |
|
|
262 | (1) |
|
6.5 Review Questions and Problems |
|
|
263 | (1) |
|
|
264 | (1) |
|
Chapter 7 Turret and Capstan Lathes |
|
|
265 | (20) |
|
|
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) |
|
|
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) |
|
|
272 | (4) |
|
|
276 | (6) |
|
|
282 | (1) |
|
|
283 | (2) |
|
Chapter 8 Automated Lathes |
|
|
285 | (60) |
|
|
285 | (1) |
|
8.2 Degree of Automation and Production Capacity |
|
|
286 | (2) |
|
8.3 Classification of Automated Lathes |
|
|
288 | (2) |
|
|
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) |
|
|
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) |
|
|
344 | (1) |
|
Chapter 9 Numerical Control and Computer Numerical Control |
|
|
345 | (70) |
|
|
345 | (5) |
|
|
350 | (5) |
|
9.2.1 Machine-Tool Axes for NC |
|
|
350 | (1) |
|
|
350 | (2) |
|
|
352 | (1) |
|
9.2.4 Zero Point Location |
|
|
353 | (1) |
|
|
354 | (1) |
|
9.2.6 Absolute and Incremental Positioning |
|
|
355 | (1) |
|
9.3 Machine Movements in Numerical Control Systems |
|
|
355 | (3) |
|
|
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) |
|
|
371 | (2) |
|
9.10 Forms of Numerical Control Instructions |
|
|
373 | (1) |
|
|
374 | (1) |
|
9.12 Feed and Spindle Speed Coding |
|
|
375 | (4) |
|
|
375 | (3) |
|
9.12.2 Spindle Speed Coding |
|
|
378 | (1) |
|
9.13 Features of Numerical Control Systems |
|
|
379 | (3) |
|
|
382 | (4) |
|
9.15 Programming Machining Centers |
|
|
386 | (9) |
|
9.15.1 Planning the Program |
|
|
386 | (4) |
|
|
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) |
|
|
409 | (1) |
|
|
409 | (1) |
|
9.18.2.3 Download the CNC Programs |
|
|
410 | (1) |
|
|
410 | (3) |
|
|
413 | (2) |
|
Chapter 10 Automated Manufacturing Systems |
|
|
415 | (30) |
|
|
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) |
|
|
436 | (2) |
|
10.6.1 Integration of AC into CAD/CAM/CIM Systems |
|
|
438 | (1) |
|
10.7 Smart Manufacturing and Artificial Intelligence |
|
|
438 | (3) |
|
|
438 | (1) |
|
|
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) |
|
|
442 | (1) |
|
|
443 | (2) |
|
Chapter 11 Machine-Tool Dynamometers |
|
|
445 | (24) |
|
|
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) |
|
|
466 | (1) |
|
|
467 | (2) |
Index |
|
469 | |