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
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
 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
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
 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
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