Fundamentals of machining processes : conventional and nonconventional processes / Hassan El-Hofy.

Includes bibliographical references (p. 443-445) and index.

Chapter 1 Machining Processes
1.1 Introduction
1.2 Historical background
1.3 Classification of machining processes
1.3.1 Machining by cutting
1.3.2 Machining by abrasion
1.3.3 Machining by erosion
1.3.3.1 Chemical and electrochemical machining
1.3.3.2 Thermal machining
1.3.4 Combined machining
1.3.5 Micromachining
1.4 Review questions
Chapter 2 Cutting Tools
2.1 Introduction
2.2 Tool geometry
2.2.1 American (ASA) system
2.2.2 Orthogonal system
2.2.3 Relationship between ASA and orthogonal systems\
2.2.4 Effect of tool setting
2.2.5 Effect of tool feed
2.2.6 Solved example
2.3 Tool materials
2.3.1 Requirements of tool materials
2.3.2 Classification of tool materials
2.3.2.1 Ferrous tool materials
2.3.2.2 Nonferrous tool materials
2.3.2.3 Nanocoated tools
2.4 Problems
2.5 Review questions
Chapter 3 Mechanics of Orthogonal Cutting
3.1 Introduction
3.2 Chip formation
3.2.1 Discontinuous chip
3.2.2 Continuous chip
3.2.3 Continuous chip with built up edge
3.3 Orthogonal cutting
3.3.1 Force diagram
3.3.2 Shear angle
3.3.3 Shear stress
3.3.4 Velocity relations
3.3.5 Shear strain
3.3.6 Rate of strain
3.3.7 The theory of Ernst and Merchant
3.3.8 The theory of Lee and Shaffer
3.3.9 Experimental verification
3.3.10 Energy considerations
3.3.11 Solved example
3.4 Problems
3.4 Review questions
Chapter 4 Economics of Machining by Cutting
4.1 Heat generation in metal cutting
4.1.1 Introduction
4.1.2 Cutting temperature
4.1.3 Temperature at shear plane
4.1.4 Factors affecting tool temperature
4.1.4.1 Machining conditions
4.1.4.2 Cutting tool
4.1.4.3 Cutting fluids
4.1.5 Temperature measurements
4.1.6 Solved example
4.2 Tool wear
4.2.1 Introduction
4.2.2 Forms of tool wear
4.2.2.1 Crater wear
4.2.2.2 Flank wear
4.2.3 Impact of tool wear
4.3 Tool life
4.3.1 Formulation of tool life equation
4.3.2 Criteria for judging the end of tool life
4.3.3 Factors affecting tool life
4.3.3.1 Cutting conditions
4.3.3.2 Tool geometry
4.3.3.3 Built up edge formation
4.3.3.4 Workpiece material
4.3.4 Solved example
4.4 Economics of metal cutting
4.4.1 Cutting speed for minimum cost
4.4.2 Cutting speed for minimum time
4.4.3 Cutting speed for maximum profit rate
4.4.4 Solved example
4.5 Problems
4.6 Review questions
Chapter 5 Cutting Cylindrical Surfaces

5.1 Introduction
5.2 Turning
5.2.1 Cutting tools
5.2.2 Cutting speed, feed , and time
5.2.3 Elements of undeformed chip
5.2.4 Cutting forces, power, and removal rate
5.2.5 Factors affecting turning forces
5.2.5.1 Factors related to the tool
5.2.5.2 Factors related to the workpiece
5.2.5.3 Factors related to cutting conditions
5.2.6 Surface finish
5.2.7 Assigning cutting variables
5.2.8 Solved example
5.3 Drilling
5.3.1 Drilling tool
5.3.2 Elements of the undeformed chip
5.3.3 Cutting forces, torque and power
5.3.4 Factors affecting forces and torque
5.3.4.1 Factors related to the workpiece
5.3.4.2 Factors related to the drill geometry
5.3.4.3 Factors related to drilling conditions
5.3.5 Drilling time
5.3.6 Dimensional accuracy
5.3.7 Surface quality
5.3.8 Selection of drilling conditions
5.3.9 Solved example
5.4 Reaming
5.4.1 Finish reamers
5.4.2 Elements of undeformed chip
5.4.3 Forces, torque and power
5.4.4 Reaming time
5.4.5 Selection of reamer diameter
5.4.6 Selection of reaming conditions
5.5 Problems
5.6 Review questions
Chapter 6 Cutting Flat Surfaces

6.1 Introduction
6.2 Shaping and planing
6.2.1 Cutting tools
6.2.2 Elements of the undeformed chip
6.2.3 Cutting forces, power, and removal rate
6.2.4 Shaping time
6.2.5 Selection of cutting variables
6.2.6 Solved example
6.3 Milling
6.3.1 Horizontal (plain) milling
6.3.1.1 Plain milling cutters
6.3.1.2 Cutting speed and feed rate
6.3.1.3 Elements of the undeformed chip
6.3.1.4 Forces, power, and removal rate
6.3.1.5 Surface roughness in plain milling
6.3.1.6 Milling time
6.3.1.7 Factors affecting cutting forces
6.3.1.8 Solved example
6.3.2 Face milling
6.3.2.1 Face milling cutters
6.3.2.2 Elements of the undeformed chip
6.3.2.3 Cutting forces and power
6.3.2.4 Surface roughness
6.3.2.5 Milling time
6.3.2.6 Solved example
6.3.3 Selection of milling conditions
6.4 Broaching
6.4.1 Broach tool
6.4.2 Chip formation in broaching
6.4.3 Broaching forces and power
6.4.4 Broaching time
6.4.5 Accuracy and surface finish
6.4.6 Broach design
6.4.7 Solved example
6.5 Problems
6.6 Review questions
Chapter 7 High Speed Machining

7.1 Introduction
7.2 History of HSM
7.3 Chip formation in HSM
7.4 Characteristics of HSM
7.5 Applications
7.6 Advantages of HSM
7.7 Limitations of HSM
7.8 Review questions
Chapter 8 Machining by Abrasion
8.1 Introduction
8.2 Grinding
8.2.1 Grinding wheels
8.2.1 Abrasive material
8.2.2 Grain size
8.2.3 Wheel bond
8.2.4 Wheel grade
8.2.5 Wheel structure
8.2.6 Grinding wheel designation
8.2.7 Wheel Shapes
8.2.8 Selection of grinding wheels
8.2.9 Wheel balancing
8.2.10 Truing and dressing
8.2.11 Temperature in grinding
8.2.2 Wheel wear
8.2.3 Economics of grinding
8.2.4 Surface roughness
8.3 Surface Grinding
8.3.1 Elements of undeformed chip
8.3.2 Cutting forces, power, and removal rate
8.3.3 Factors affecting the grinding forces
8.3.4 Grinding time
8.3.5 Solved example
8.3.6 Surface grinding operations
8.3.6.1 Plain (periphery) and face grinding with reciprocating feed
8.3.6.2 Surface grinding with a rotating table
8.3.6.3 Creep feed grinding
8.4 Cylindrical Grinding
8.4.1 Elements of undeformed chip
8.4.2 Forces, power, and removal rate
8.4.3 Factors affecting the grinding forces
8.4.4 Factors affecting surface roughness
8.4.5 Solved example
8.4.6 Cylindrical grinding operations
8.4.6.1 External cylindrical grinding
8.4.6.2 External Centerless grinding
8.4.6.3 Internal cylindrical grinding
8.4.6.4 Internal centerless grinding
8.5 Wheel speed and workpiece feed
8.6 Problems
8.7 Review questions
Chapter 9 Abrasive Finishing Processes
9.1 Introduction
9.2 Honing
9.2.1 Honing kinematics
9.2.2 Process components
9.2.3 Process description
9.2.4 Process characteristics
9.3 Lapping
9.3.1 Process components
9.3.2 Mechanics of lapping
9.3.3 Process characteristics
9.3.4 Lapping operations
9.4 Superfinishing
9.4.1 Kinematics of superfinishing
9.4.2 Process characteristics
9.5 Polishing
9.6 Buffing
9.7 Review questions
Chapter 10 Modern Abrasive Processes
10.1 Ultrasonic machining
10.1.1 Mechanism of material removal
10.1.2 Solved example
10.1.3 Factors affecting material removal rate
10.1.4 Dimensional accuracy
10.1.5 Surface quality
10.1.6 Applications
10.2 Abrasive jet machining
10.2.1 Material removal rate
10.2.2 Applications
10.3 Abrasive water jet machining
10.3.1 Process characteristics
10.4 Abrasive flow machining
10.5 Magnetic abrasive machining
10.5.1 Process characteristics
10.5.2 Applications
10.6 Problems
10.7 Review questions
Chapter 11 Machining by Electrochemical Erosion

11.1 Introduction
11.2 Principles of ECM
11.3 Advantages and disadvantages of ECM
11.4 Material removal rate by ECM
11.5 Solved example
11.6 ECM equipment
11.7 Process characteristics
11.8 Economics of ECM
11.9 ECM applications
11.10 Chemical machining
11.11 Problems
11.12 Review questions
Chapter 12 Machining by Thermal Erosion

12.1 Introduction
12.2 Electrodischarge machining
12.2.1 Mechanism of material removal
12.2.2 EDM machine
12.2.3 Material removal rates
12.2.4 Surface integrity
12.2.5 Heat affected zone
12.2.6 Applications
12.3 Laser beam machining
12.3.1 Material removal mechanism
12.3.2 Applications
12.4 Electron beam machining
12.4.1 Material removal process
12.4.2 Applications
12.5 Ion beam machining
12.6 Plasma beam machining
12.6.1 Material removal rate
12.6.2 Applications
12.7 Problems
12.8 Review questions
Chapter 13 Combined Machining Processes

13.1 Introduction
13.2 Electrochemical assisted processes
13.2.1 Electrochemical grinding
13.2.2 Electrochemical honing
13.2.3 Electrochemical superfinishing
13.2.4 Electrochemical buffing
13.2.5 Ultrasonic assisted electrochemical machining
13.3 Thermal assisted processes
13.3.1 Electro erosion dissolution machining
13.3.2 Abrasive electrodischarge grinding
13.3.3 Abrasive electrical discharge machining\
13.3.4 EDM with ultrasonic assistance
13.3.5 Electrochemical discharge grinding:
13.3.6 Brush erosion dissolution mechanical machining
13.4 Problems
13.5 Review questions
Chapter 14 Micromachining

14.1 Introduction
14.2 Micromachining by cutting
14.2.1 Diamond micro turning
14.2.2 Micro drilling
14.3 Abrasive micromachining
14.3.1 Micro grinding
14.3.2 Magnetic abrasive micromachining and finishing
14.3.3 Micro superfinishing
14.3.4 Micro lapping
14.3.5 Microultrasonic machining
14.4 Nonconventional micromachining
14.4.1 Micromachining by thermal erosion
14.4.1.1 Micro EDM
14.4.1.2 Laser micromachining
14.4.2 Micromachining by electrochemical erosion
14.4.3 Combined micromachining processes
14.5 Review questions
15 References
16 Subject index

Fundamentals of Machining Processes is the first book to collect all of the major conventional and nonconventional machining methods into a single reference, from cutting and abrasive processes to erosion, hybrid, and micromachining processes. It begins with an introduction to the various machining processes, followed by the mechanics and economics of cutting, abrasive, erosion, and micromachining processes. The author discusses the advantages, limitations, and applications for each process along with the factors influencing its economics. Extensive worked examples, illustrations, and exercises reinforce a practical understanding of the concepts presented throughout the book.