Fundamentals of Machining Processes: Conventional and Nonconventional Processes
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Summary
Machining remains a hugely important process in modern engineering and manufacturing practice, and students need to be aware of the vast host of methods and technologies available to meet all sorts of precision and surface finish requirements. Fundamentals of Machining Processes: Conventional and Nonconventional Processes is the first textbook to collect all of the major methods into a single reference, from cutting and abrasive processes to erosion, hybrid, and micromachining processes.
A Solid Foundation
The text begins with an introduction to the various machining processes, followed by detailed discussions of cutting tool materials and geometry, mechanics of orthogonal cutting, the various factors affecting the economics of machining, and cutting methods for both flat and cylindrical surfaces. The author then shifts focus to high-speed machining and abrasive processes, including abrasive finishing and advanced processes such as ultrasonic and abrasive jet machining.
A Firm Step Forward
After laying a groundwork in the conventional processes, El-Hofy delves into modern machining topics. He explains electrochemical and thermal erosion techniques, combined machining processes, and the various micromachining techniques based on the previously discusses processes.
Extensive worked examples, illustrations, and homework problems reinforce a practical understanding of the concepts. Reflecting the author's more than 30 years of industrial and teaching experience, Fundamentals of Machining Processes is a resource that students will carry with them well into their careers.
Table of Contents
MACHINING PROCESSES
Introduction
Historical Background
Classification of Machining Processes
Review Questions
CUTTING TOOLS
Introduction
Tool Geometry
Tool Materials
Problems
Review Questions
MECHANICS OF ORTHOGONAL CUTTING
Introduction
Chip Formation
Orthogonal Cutting
Problems
Review Questions
ECONOMICS OF MACHINING BY CUTTING
Heat Generation in Metal Cutting
Tool Wear
Tool Life
Economics of Metal Cutting
Problems
Review Questions
CUTTING CYLINDRICAL SURFACES
Introduction
Turning
Drilling
Reaming
Problems
Review Questions
CUTTING FLAT SURFACES
Introduction
Shaping and Planing
Milling
Broaching
Problems
Review Questions
HIGH-SPEED MACHINING
Introduction
History of HSM
Chip Formation in HSM
Characteristics of HSM
Applications
Advantages of HSM
Limitations of HSM
Review Questions
MACHINING BY ABRASION
Introduction
Grinding
Surface Grinding
Cylindrical Grinding
Wheel Speed and Workpiece Feed
Problems
Review Questions
ABRASIVE FINISHING PROCESSES
Introduction
Honing
Lapping
Superfinishing
Polishing
Buffing
Review Questions
MODERN ABRASIVE PROCESSES
Ultrasonic Machining
Abrasive Jet Machining
Abrasive Water Jet Machining
Abrasive Flow Machining
Magnetic Abrasive Machining
Problems
Review Questions
MACHINING BY ELECTROCHEMICAL EROSION
Introduction
Principles of ECM
Advantages and Disadvantages of ECM
Material Removal Rate by ECM
Solved Example
ECM Equipment
Process Characteristics
Economics of ECM
ECM Applications
Chemical Machining
Problems
Review Questions
MACHINING BY THERMAL EROSION
Introduction
Electrodischarge Machining
Laser Beam Machining
Electron Beam Machining
Ion Beam Machining
Plasma Beam Machining
Problems
Review Questions
COMBINED MACHINING PROCESSES
Introduction
Electrochemical Assisted Processes
Thermal-Assisted Processes
Problems
Review Questions
MICROMACHINING
Introduction
Conventional Micromachining
Abrasive Micromachining
Nonconventional Micromachining
Review Questions
REFERENCES
INDEX
Editorial Reviews
"I am pleased and proud to introduce this book. It will fill a much-needed niche in machining textbooks … [and for] those in engineering practice. … Throughout the book I welcomed the use of solved problems and review questions to test the knowledge and understanding of the reader."
-From the foreword by J.A. McGeough, Professor Emeritus, The University of Edinburgh, Scotland
