TY  - BOOK
AU  - El-Hofy,Hassan
TI  - Fundamentals of machining processes: conventional and nonconventional processes 
SN  - 0849372887 (alk. paper)
AV  - TJ1185 .E448 2007
U1  - 671.35 22
PY  - 2007///
CY  - Boca Raton, FL
PB  - CRC/Taylor & Francis
KW  - Machining
N1  - 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	
N2  - 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.


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