Fundamentals of Machining Processes: Conventional and Nonconventional Processes

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