PART IVMETAL REMOVAL PROCESSES
Chapter 10Fundamentals of Metal Machining
10.1Introduction
10.2Mechanics of Machining
10.2.1Types of Cutting
10.2.2Chip Formation
10.3Cutting Force and Power
10.3.1Cutting Force
10.3.2Power
10.4Thermodynamics of Cutting
10.4.1Cutting Heat
10.4.2Cutting Temperature
10.5Tool Wear and Tool Life
10.5.1Tool Wear
10.5.2Taylor’s Tool Life Theory
10.6Cutting Fluids
10.6.1Methods of Cutting Fluid Application
10.6.2Types of Cutting Fluids
10.7Surface Finish
10.7.1ISO Surface Finish
10.8Cutting Tool Materials
10.8.1Tool Steels and Cast Alloys
10.8.2Carbides
10.9Machinability
10.9.1Effects of Chemical Composition and Physical Characteristics of Materials
10.10Selection of Cutting Conditions and Machining Economics
10.10.1Selecting Cutting Conditions
10.10.2Machining Economics
Chapter 11Machining Processes
11.1Introduction
11.2Turning
11.2.1Machining Operations Related to Turning
11.2.2Cutting Conditions in Turning
11.2.3Cutting Tools for Turning Operations
11.2.4Lathes
11.2.5Boring
11.3Drilling
11.3.1Types of Drills
11.3.2Cutting Conditions in Drilling
11.3.3Reaming
11.3.4Machines for Drilling
11.4Milling
11.4.1Types of Milling Operations
11.4.2Generation of Surfaces in Milling
11.4.3Cutting Conditions in Milling
11.4.4Milling Cutters
11.4.5Milling Machines
11.5Sawing
11.5.1Types of Sawing
11.5.2Saw Blades
11.6Planing and Shaping
11.6.1Planing and Planers
11.6.2Shaping and Shapers
11.6.3Cutting Conditions
11.7Broaching
11.7.1Broaches
11.7.2Broaching Machines
11.8Gear Manufacturing
11.8.1Gear Terminology and Definitions
11.8.2Methods of Manufacturing Gears
11.8.3Gear Finishing Processes
Chapter 12Abrasive Machining Processes
12.1Introduction
12.2Abrasives
12.2.1Abrasive Grain Size and Geometry
12.3Grinding
12.3.1Grinding Wheels
12.3.2Analysis of the Grinding Process
12.3.3Grinding Operations and Machines
12.4Finishing Operations
12.4.1Honing
12.4.2Lapping
12.4.3Superfinishing
12.4.4Polishing and Buffing
Chapter 13Nontraditional Machining Processes
13.1Introduction
13.2Mechanical Energy Processes
13.2.1Ultrasonic Machining
13.2.2Water-Jet Cutting
13.3Electrochemical Machining Processes
13.3.1Electrochemical Machining
13.3.2Electrochemical Grinding
13.4Thermal Energy Processes
13.4.1Electric Discharge Processes
13.4.2Laser Beam Machining
13.4.3Electron Beam Machining
13.5Chemical Machining
13.5.1Chemical Milling
Index
The study of manufacturing engineering is an important discipline in any industrial society, and within that discipline one of the more important subjects is manufacturing processes. This book is intended to treat one broad and challenging part of this subject—metal shaping processes. It is a comprehensive text written mainly for students in mechanical, industrial, and manufacturing engineering programs at both the associate and bachelor degree levels. The fundamentals of metal shaping processes and their relevant applications are presented step-by-step so that the reader can clearly assess the capabilities,