See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/259800842

Manufacturing Technology, Vol. 2 Metal Cutting and Machine Tools

Book · May 2013

CITATIONS READS

47 25,876

1 author:

Nageswara Rao Posinasetti

University of Northern Iowa
197 PUBLICATIONS   478 CITATIONS   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Diecasting View project

All content following this page was uploaded by Nageswara Rao Posinasetti on 09 February 2014.

The user has requested enhancement of the downloaded file.

 Contents
Preface to the Third Edition xiii

1. Introduction 1
1.1 Introduction to Material-Removal Processes  1
1.2 Variety of Machine Tools  2

2 Metal Cutting 5
2.1 Introduction  5
2.2 Chip Formation  7
2.3 Shear Zone  10
2.4 Orthogonal Cutting  10
2.5 Shear Angle and its Relevance  22
2.6 Cutting-Tool Geometry  25
2.7 Dynamometers  30
2.8 Cutting-Tool Materials  32
2.9 Thermal Aspects  44
2.10 Tool Wear and Tool Life  47
2.11 Surface Finish  54
2.12 Cutting Fluids  56
2.13 Empirical and Analytical Determination of Cutting Forces  60
2.14 Economics  61
Summary  69
Questions  70
Problems  72
Multiple-Choice Questions  77
Answers to Multiple Choice Questions  79

3. Machine Tools 80
3.1 Introduction  80
3.2 Classification of Machine Tools  81
3.3 Generating and Forming  82

MT_Prelims.indd 7 2/12/2013 10:09:28 AM

 viii Contents

3.4 Methods of Generating Surfaces  83

3.5 Accuracy and Finish Achievable  86
3.6 Basic Elements of Machine Tools  88
3.7 Support Structures  88
3.8 Power Transmission  90
3.9 Actuation Systems  94
3.10 Guideways  96
3.11 General Work-Holding Methods  102
Summary  103
Questions  103
Multiple-Choice Questions  104
Answers to Multiple-Choice Questions  105

4. Centre Lathe 106

4.1 Introduction  106
4.2 Constructional Features of a Centre Lathe  107
4.3 Aids for Support and Location  110
4.4 Cutting Tools  116
4.5 Operations Performed in a Centre Lathe  123
4.6 Taper-Turning Methods  126
4.7 Thread-Cutting Methods  131
4.8 Special Attachments  135
4.9 Machining Time and Power Estimation  136
4.10 Typical Set-ups  144
Summary  147
Questions  147
Problems  148
Multiple-Choice Questions  149
Answers to Multiple-Choice Questions  151

5. Special-Purpose Lathes 152

5.1 Limitations of A Centre Lathe  152
5.2 Capstan and Turret Lathes  153
5.3 Automatic Lathes  161
5.4 Tooling Layout and Cam Design for Automatic Lathes  167
Summary  175
Questions  175
Multiple-Choice Questions  176
Answers to Multiple-Choice Questions  176

MT_Prelims.indd 8 2/12/2013 10:09:28 AM

 Contents ix

6. Reciprocating Machine Tools 177

6.1 Introduction  177
6.2 Shaper  177
6.3 Planing Machine (Planer)  188
6.4 Slotting Machine (Slotter)  193
6.5 Comparison of Reciprocating Machine Tools  195
Summary  195
Questions  196
Problems  196
Multiple-Choice Questions  197
Answers to Multiple-Choice Questions  198

7. Milling 199
7.1 Introduction  199
7.2 Types of Milling Machines  200
7.3 Milling Cutters  203
7.4 Milling Operations  212
7.5 Dividing Head  215
7.6 Milling Mechanics  223
7.7 Milling Time and Power Estimation  227
7.8 Special Set-Ups  233
Summary  236
Review Questions  237
Problems  237
Multiple-Choice Questions  239
Answers to Multiple-Choice Questions  240

8. Hole-Making Operations 241

8.1 Introduction  241
8.2 Drilling  242
8.3 Reaming  255
8.4 Boring  258
8.5 Tapping  263
8.6 Other Hole-Making Operations  266
Summary  268
Questions  268
Problems  269
Multiple-Choice Questions  269
Answers to Multiple-Choice Questions  270

MT_Prelims.indd 9 2/12/2013 10:09:28 AM

 x Contents

9. Abrasive Processes 271

9.1 Introduction  271
9.2 Grinding Wheel: Designation and Selection  272
9.3 Types of Grinding Machines  280
9.4 Grinding Process  285
9.5 Grinding-Process Parameters  289
9.6 Creep-Feed Grinding  292
9.7 Honing  293
9.8 Lapping  295
9.9 Other Finishing Processes  297
Summary  300
Questions  300
Problems  301
Multiple-Choice Questions  302
Answers to Multiple-Choice Questions  303

10. Other Machine Tools 304

10.1 Sawing  304
10.2 Broaching  308
10.3 Gear Cutting  313
Summary  321
Review Questions  321
Multiple-Choice Questions  322
Answers to Multiple-Choice Questions  323

11. Unconventional Machining Processes 324

11.1 Need For Unconventional Processes  324
11.2 Electric-Discharge Machining  326
11.3 Electrochemical Machining  346
11.4 Ultrasonic Machining  355
11.5 Chemical Machining  358
11.6 Laser-Beam Machining  361
11.7 Abrasive Water-Jet Machining (AWJM)  364
11.8 Electron-Beam Machining (EBM)  370
11.9 Ion-Beam Machining (IBM)  372
11.10 Plasma-Arc Machining (PAM)  373
Summary  375
Questions  376
Multiple-Choice Questions  377
Answers to Multiple Choice Questions  379

MT_Prelims.indd 10 2/12/2013 10:09:28 AM

 Contents xi

12. Machine-Tool Testing 380

12.1 Introduction  380
12.2 Measuring Instruments Used for Testing  380
12.3 Test Procedures  381
12.4 Acceptance Tests  381
Summary  385

13. Designing for Machining 386

13.1 Introduction  386
13.2 General Guidelines for Design for Machining (DFM)  386
13.3 Design for Turning  389
13.4 Design for Hole-Making Operations  391
Summary  393

14. Jigs and Fixtures 394

14.1 Introduction  394
14.2 Functional Surfaces  397
14.3 Location Principles  399
14.4 Locating Devices  401
14.5 Clamping Devices  406
14.6 Jigs  410
14.7 Designing a Jig  417
14.8 Fixtures  421
Summary  426
Review Questions  426
Multiple-Choice Questions  427
Answers to Multiple Choice Questions  428

15. Metrology 429

15.1 Introduction  429
15.2 Tolerances, Limits and Fits  430
15.3 Linear Measurement  436
15.4 Angular Measurement  442
15.5 Thread Measurement  444
15.6 Surface Texture  446
15.7 Gauges and Gauge Design  448
Summary  450
Review Questions  451
Multiple-Choice Questions  451
Answers to Multiple Choice Questions  452

MT_Prelims.indd 11 2/12/2013 10:09:28 AM

 xii Contents

16. Numerical Control of Machine Tools 453

16.1 Introduction  453
16.2 Numerical Control  454
16.3 NC Machine Tools  457
16.4 Part-Programming Fundamentals  464
16.5 Manual Part-Programming Methods  468
16.6 Computer-Aided Part Programming (CAP)  489
Summary  503
Questions  503
Problems  504
Multiple-Choice Questions  507
Answers to Multiple-Choice Questions  507

Bibliograhy 508

Index 511

MT_Prelims.indd
View publication stats 12 2/12/2013 10:09:28 AM