Fundamentals of Metal Machining and Machine Tools book cover

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Fundamentals of Metal Machining and Machine Tools book cover

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3rd Edition

Fundamentals of Metal Machining and Machine Tools

Copyright Year 2005

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Book Description

In the more than 15 years since the second edition of Fundamentals of Machining and Machine Tools was published, the industry has seen many changes. Students must keep up with developments in analytical modeling of machining processes, modern cutting tool materials, and how these changes affect the economics of machining. With coverage reflecting state-of-the-art industry practice, Fundamentals of Machining and Machine Tools, Third Edition emphasizes underlying concepts, analytical methods, and economic considerations, requiring only basic mathematics and physics.

This book thoroughly illustrates the causes of various phenomena and their effects on machining practice. The authors include several descriptions of modern analytical methods, outlining the strengths and weaknesses of the various modeling approaches.

What's New in the Third Edition?

  • Recent advances in super-hard cutting tool materials, tool geometries, and surface coatings
  • Advances in high-speed machining and hard machining
  • New trends in cutting fluid applications, including dry and minimum-quantity lubrication machining
  • New developments in tool geometries for chip breaking and chip control
  • Improvements in cost modeling of machining processes, including application to grinding processes

    Supplying abundant examples, illustrations, and homework problems, Fundamentals of Machining and Machine Tools, Third Edition is an ideal textbook for senior undergraduate and graduate students studying metal cutting, machining, machine tool technology, machining applications, and manufacturing processes.

    • Table of Contents

    CONVENTIONS USED IN THIS BOOK
    Standardization
    Introduction to the International (SI) System of Units
    MACHINE TOOLS AND MACHINING OPERATIONS
    Introduction
    Generating Motions of Machine Tools
    Machines Using Single-Point Tools
    Machines Using Multipoint Tools
    Machines Using Abrasive Wheels
    Summary of Machine Tool Characteristics and Machining Equations
    Problems
    References
    MECHANICS OF METAL CUTTING
    Introduction
    Terms and Definitions
    Chip Formation
    The Forces Acting on the Cutting Tool and Their Measurement
    Specific Cutting Energy
    Plowing Force and the "Size Effect"
    The Apparent Mean Shear Strength of the Work Material
    Chip Thickness
    Friction in Metal Cutting
    Analytical Modeling of Machining Operations
    Problems
    References
    TEMPERATURES IN METAL CUTTING
    Heat Generation in Metal Cutting
    Heat Transfer in a Moving Material
    Temperature Distribution in Metal Cutting
    The Measurement of Cutting Temperatures
    Problems
    References
    TOOL LIFE AND TOOL MATERIALS
    Introduction
    Progressive Tool Wear
    Forms of Wear in Metal Cutting
    The Tool Material
    Tool Geometries
    The Work Material
    High Speed Machining
    Hard Machining
    Problems
    References
    CUTTING FLUIDS AND SURFACE ROUGHNESS
    Cutting Fluids
    The Action of Coolants
    The Action of Lubricants
    Application of Cutting Fluids
    Cutting Fluid Maintenance
    Environmental Considerations
    Disposal of Cutting Fluids
    Dry Cutting and Minimum Quantity Lubrication
    Surface Roughness
    Tool Geometries for Improved Surface Finish
    Burr Formation in Machining
    Problems
    References
    ECONOMICS OF METAL-CUTTING OPERATIONS
    Introduction
    Choice of Feed
    Choice of Cutting Speed
    Tool Life for Minimum Cost and Minimum Production Time
    Estimation of Factors Needed to Determine Optimum Conditions
    Example of a Constant-Cutting-Speed Operation
    Machining at Maximum Efficiency
    Facing Operations
    Operations with Interrupted Cuts
    Economics of Various Tool Materials and Tool Designs
    Machinability Data Systems
    Limitations of Available Machinability Data
    Problems
    References
    NOMENCLATURE OF CUTTING TOOLS
    Introduction
    Systems of Cutting-Tool Nomenclature
    International Standard
    Problems
    References
    CHIP CONTROL
    Introduction
    Chip Breakers
    Prediction of Radius of Chip Curvature
    Prediction of Chip Breaking Performance
    Tool Wear During Chip Breaking
    Problems
    References
    MACHINE TOOL VIBRATIONS
    Introduction
    Forced Vibrations
    Self-Excited Vibrations (Chatter)
    Determination of Frequency Response Loci
    Dynamic Acceptance Tests for Machine Tools
    Improving Machine Tool Stability
    Problems
    References
    GRINDING
    Introduction
    The Grinding Wheel
    Effect of Grinding Conditions on Wheel Behavior
    Determination of the Density of Active Grains
    Testing of Grinding Wheels
    Dressing and Truing of Grinding Wheels
    Analysis of the Grinding Process
    Thermal Effects in Grinding
    Cutting Fluids in Grinding
    Grinding-Wheel Wear
    Nonconventional Grinding Operations
    Problems
    References
    MANUFACTURING SYSTEMS AND AUTOMATION
    Introduction
    Types of Production
    Types of Facilities Layout
    Types of Automation
    Transfer Machines
    Automatic Machines
    Numerically Controlled (NC) Machine Tools
    Comparison of the Economics of Various Automation Systems
    Handling of Components in Batch Production
    Flexible Manufacturing Systems
    Problems
    References
    COMPUTER-AIDED MANUFACTURING
    Introduction
    Scope of CAD/CAM
    Process-Planning Tasks
    Computer-Aided Process Planning
    Processing of NC Programs
    Computer-Aided NC Processing
    Numerical Control Processing Languages
    NC Programming Using APT-Based Languages
    Graphics-Based NC Processing Systems
    References
    DESIGN FOR MACHINING
    Introduction
    Standardization
    Choice of Work Material
    Shape of Work Material
    Shape of Component
    Assembly of Components
    Accuracy and Surface Finish
    Summary of Design Guidelines
    Cost Estimating for Machined Components
    Problems
    References
    NONCONVENTIONAL MACHINING PROCESSES
    Introduction
    Range of Nonconventional Machining Processes
    Ultrasonic Machining
    Water-Jet Machining
    Abrasive-Jet Machining
    Chemical Machining
    Electrochemical Machining
    Electrolytic Grinding
    Electrical-Discharge Machining
    Wire Electrical-Discharge Machining
    Laser-Beam Machining
    Electron-Beam Machining
    Plasma-Arc Cutting
    Comparative Performance of Cutting Processes
    Problems
    References
    NOMENCLATURE
    INDEX