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El. knyga: Traditional Machining Technology 2nd edition [Taylor & Francis e-book]

(Egypt-Japan University of Science and Technology), (Alexandria University, Egypt)
  • Formatas: 474 pages, 58 Tables, black and white
  • Išleidimo metai: 11-Aug-2020
  • Leidėjas: CRC Press
  • ISBN-13: 9781003055303
  • Taylor & Francis e-book
  • Kaina: 276,97 €*
  • * this price gives unlimited concurrent access for unlimited time
  • Standartinė kaina: 395,67 €
  • Sutaupote 30%
  • Formatas: 474 pages, 58 Tables, black and white
  • Išleidimo metai: 11-Aug-2020
  • Leidėjas: CRC Press
  • ISBN-13: 9781003055303
"This volume describes the fundamentals, basic elements, and operations of general-purpose metal cutting and abrasive machine tools used for the production and grinding of cylindrical and flat surfaces by turning, drilling, and reaming, shaping and planning, and milling processes. Special purpose machines and operations used for thread cutting, 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. The treatment throughout the book is aimed at motivating and challenging the reader to explore technologies and economically viable solutions regarding optimum selection of machining operationsfor a given task"--

Traditional Machining Technology describes the fundamentals, basic elements, and operations of general-purpose metal cutting and abrasive machine tools used for the production and grinding of cylindrical and flat surfaces by turning, drilling, and reaming; shaping and planing; and milling processes.

Special-purpose machines and operations used for thread cutting, gear cutting, and broaching processes are included along with semiautomatic, automatic, NC, and CNC machine tools; operations, tooling, mechanisms, accessories, jigs and fixtures, and machine-tool dynamometry are discussed. The treatment throughout the book is aimed at motivating and challenging the reader to explore technologies and economically viable solutions regarding the optimum selection of machining operations for a given task.

This book will be useful to professionals, students, and companies in the industrial, manufacturing, mechanical, materials, and production engineering fields.

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 Microtinishing 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(4)
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
Helmi 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 was 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. On early 1970s, he established the first NTM-research laboratory in Alexandria University, and may be in the whole region. Since that time, he carried out intensive research in his fields of specialization, and supervised many Ph.D. and M. Sc. theses.

Between 1975 and 1998, Professor Youssef was a visiting Professor in Arabic universities, such as El-Fateh University in Tripoli, the Technical University in Baghdad, King Saud University (KSU) in Riyadh, and Beirut Arab University (BAU) in Beirut. Beside his teaching activities in these universities, he established laboratories, and supervised many M.Sc. theses. Moreover, he was a visiting professor in different academic institutions in Egypt and abroad. During 1982, he was a visiting Professor in the University of Rostock, Germany, and during the years 1997 1998 he was a visiting Professor in the University of Bremen, Germany.

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, two of which are single authored. The first is in Arabic, titled Nontraditional Machining Processes, Theory and Practice, published in 2005, and the other is titled Machining of Stainless Steels and Superalloys, Traditional and Nontraditional Techniques, published by Wiley in 2016. Other two co-authored books are published by CRC in 2008 and 2011, respectively. The first is on Machining Technology, while the second deals with the Manufacturing Technology.

Currently, Professor Youssef is an emeritus Professor in PED, Alexandria University. His work in the time being involves developing courses and conducting research in the areas of metal cutting and nontraditional machining.

Hassan El-Hofy received his BSc in Production Engineering from Alexandria University (AU), Egypt in 1976 and his MSc in 1979. Following his MSc, he worked as an assistant lecturer in the same department. In October 1980 he left to Aberdeen University in Scotland, UK and began his PhD work with Professor J. McGeough in electrochemical discharge machining. 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 AU and resumed his work as an assistant professor. In 1990, he was promoted to the rank of an associate professor. He was on sabbatical as a visiting professor at Al-Fateh University in Tripoli between 1989 and 1994.

In July 1994, he returned back to AU, and was promoted to the rank of full professor in November 1997. From September 2000, he worked as a professor for Qatar University (QU). He chaired the accreditation committee for mechanical engineering program toward ABET Substantial Equivalency Recognition that has been granted to the College of Engineering programs (QU) in 2005. He received the Qatar University Award and a certificate of appreciation for his role in that event.

Professor El-Hofy wrote his first book entitled Advanced Machining Processes: Nontraditional and Hybrid Processes, which was published by McGraw Hill Co in 2005. The third edition of his second book entitled Fundamentals of Machining ProcessesConventional and Nonconventional Processes appeared in November 2018 by Taylor & Francis Group, CRC Press. He also coauthored the 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 advanced machining. He serves as a consulting editor to many international journals and is a regular participant in many international conferences.

Between August, 2007, and August 2010 he became the chairman of the Department of Production Engineering, AU. In October 2011 he was nominated as the Vice Dean for Education and Students affairs, college of Engineering AU. Between December 2012 and February 2018 he was the Dean of the Innovative Design Engineering (IDE) School at Egypt-Japan University of Science and Technology (E-JUST) in Alexandria, Egypt. He worked as an 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 (IME) at E-JUST.