Preface |
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xix | |
Foreword |
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xxiii | |
Acknowledgments |
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xxv | |
Abbreviations |
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xxvii | |
List of Symbols |
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xxxi | |
Greek Symbols |
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xl | |
Author |
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xlv | |
Chapter 1 Machining Processes |
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1 | (16) |
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1 | (1) |
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1.2 Historical Background |
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2 | (1) |
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1.3 Classification of Machining Processes |
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3 | (10) |
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1.3.1 Machining by Cutting |
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4 | (2) |
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4 | (1) |
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1.3.1.2 Generation Cutting |
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5 | (1) |
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1.3.1.3 Form and Generation Cutting |
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5 | (1) |
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1.3.2 Machining by Abrasion |
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6 | (3) |
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1.3.3 Machining by Erosion |
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9 | (1) |
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1.3.3.1 Chemical and Electrochemical Erosion |
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10 | (1) |
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10 | (1) |
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10 | (1) |
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11 | (1) |
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1.3.6 Assisted Machining Processes |
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12 | (1) |
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1.4 Machining Hard-to-Cut Materials |
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13 | (1) |
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1.5 Variables of Machining Processes |
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13 | (1) |
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1.6 Machining Process Selection |
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14 | (1) |
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15 | (2) |
Chapter 2 Cutting Tools |
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17 | (36) |
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17 | (3) |
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2.2 Geometry of Single-Point Tools |
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20 | (9) |
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2.2.1 American Standard Association (Tool-in-Hand) (Coordinate) System |
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21 | (1) |
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2.2.2 Tool Angles in Orthogonal System of Planes |
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21 | (4) |
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2.2.3 Relationship between the ASA and Orthogonal Systems |
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25 | (1) |
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2.2.4 Effect of Tool Setting |
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26 | (1) |
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2.2.5 Effect of Tool Feed Motion |
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27 | (1) |
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28 | (1) |
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2.3 Geometry of Multipoint Cutting Tools |
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29 | (6) |
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29 | (2) |
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31 | (1) |
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32 | (1) |
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33 | (1) |
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2.3.5 Plain Milling Cutters |
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34 | (1) |
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35 | (14) |
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2.4.1 Requirements of Tool Materials |
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35 | (1) |
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2.4.2 Classification of Tool Materials |
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36 | (17) |
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2.4.2.1 Ferrous Tool Materials |
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36 | (4) |
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2.4.2.2 Nonferrous Tool Materials |
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40 | (6) |
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46 | (3) |
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49 | (1) |
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50 | (3) |
Chapter 3 Mechanics of Orthogonal Cutting |
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53 | (36) |
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53 | (1) |
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53 | (4) |
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53 | (2) |
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55 | (2) |
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3.2.3 Continuous Chip with a Built-up Edge |
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57 | (1) |
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57 | (13) |
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59 | (2) |
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61 | (2) |
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63 | (1) |
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63 | (1) |
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64 | (1) |
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65 | (1) |
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3.3.7 Theory of Ernst and Merchant |
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65 | (2) |
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3.3.8 Theory of Lee and Shaffer |
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67 | (1) |
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3.3.9 Experimental Verification |
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68 | (1) |
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3.3.10 Energy Consideration |
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68 | (1) |
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69 | (1) |
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3.4 Heat Generation in Metal Cutting |
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70 | (14) |
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3.4.1 Cutting Tool Temperature |
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73 | (1) |
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3.4.2 Temperature at Shear Plane |
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74 | (1) |
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3.4.3 Factors Affecting the Tool Temperature |
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75 | (7) |
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3.4.3.1 Machining Conditions |
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76 | (1) |
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76 | (1) |
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76 | (5) |
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3.4.3.4 Minimum Quantity Lubrication |
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81 | (1) |
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82 | (2) |
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84 | (3) |
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87 | (2) |
Chapter 4 Tool Wear, Tool Life, and Economics of Metal Cutting |
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89 | (24) |
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89 | (5) |
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89 | (1) |
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89 | (5) |
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91 | (1) |
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92 | (2) |
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4.1.3 Impact of Tool Wear |
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94 | (1) |
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94 | (7) |
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4.2.1 Formulation of Tool-life Equation |
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95 | (1) |
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4.2.2 Criteria for Judging the End of Tool Life |
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96 | (1) |
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4.2.3 Factors Affecting Tool Life |
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97 | (3) |
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4.2.3.1 Cutting Conditions |
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97 | (1) |
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98 | (1) |
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4.2.3.3 Built-Up Edge Formation |
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98 | (1) |
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98 | (1) |
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4.2.3.5 Workpiece Material |
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99 | (1) |
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4.2.3.6 Rigidity of the Machine Tool |
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99 | (1) |
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99 | (1) |
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100 | (1) |
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4.3 Economics of Metal Cutting |
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101 | (9) |
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4.3.1 Cutting Speed for Minimum Cost |
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101 | (4) |
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4.3.2 Cutting Speed for Minimum Time |
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105 | (2) |
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4.3.3 Cutting Speed for Maximum Profit Rate |
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107 | (2) |
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109 | (1) |
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110 | (1) |
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111 | (2) |
Chapter 5 Cutting Cylindrical Surfaces |
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113 | (46) |
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113 | (1) |
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113 | (14) |
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114 | (1) |
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5.2.2 Cutting Speed, Feed, and Machining Time |
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115 | (1) |
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5.2.3 Elements of Undeformed Chip |
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116 | (1) |
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5.2.4 Cutting Forces, Power, and Removal Rate |
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117 | (2) |
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5.2.5 Factors Affecting the Turning Forces |
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119 | (3) |
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5.2.5.1 Factors Related to Tool |
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119 | (2) |
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5.2.5.2 Factors Related to Workpiece |
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121 | (1) |
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5.2.5.3 Factors Related to Cutting Conditions |
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121 | (1) |
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122 | (2) |
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5.2.7 Assigning the Cutting Variables |
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124 | (1) |
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124 | (3) |
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127 | (15) |
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127 | (2) |
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5.3.2 Elements of Undeformed Chip |
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129 | (3) |
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5.3.3 Cutting Forces, Torque, and Power |
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132 | (3) |
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5.3.4 Factors Affecting the Drilling Forces |
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135 | (1) |
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5.3.4.1 Factors Related to the Workpiece |
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135 | (1) |
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5.3.4.2 Factors Related to the Drill Geometry |
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135 | (1) |
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5.3.4.3 Factors Related to Drilling Conditions |
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136 | (1) |
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136 | (1) |
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5.3.6 Dimensional Accuracy |
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137 | (2) |
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139 | (1) |
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5.3.8 Selection of Drilling Conditions |
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139 | (1) |
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139 | (3) |
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142 | (10) |
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144 | (1) |
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5.4.2 Elements of Undeformed Chip |
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145 | (1) |
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5.4.3 Forces, Torque, and Power in Reaming |
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146 | (1) |
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147 | (1) |
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5.4.5 Selection of the Reamer Diameter |
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148 | (1) |
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5.4.6 Selection of Reaming Conditions |
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149 | (2) |
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151 | (1) |
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152 | (4) |
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152 | (2) |
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154 | (2) |
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156 | (3) |
Chapter 6 Cutting Flat Surfaces |
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159 | (52) |
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159 | (1) |
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159 | (9) |
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6.2.1 Shaper and Planer Tools |
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159 | (1) |
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6.2.2 Elements of Undeformed Chip |
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159 | (4) |
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6.2.3 Cutting Forces, Power, and Removal Rate |
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163 | (1) |
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164 | (1) |
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6.2.5 Selection of Cutting Variables |
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165 | (1) |
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165 | (3) |
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168 | (22) |
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6.3.1 Horizontal (Plain) Milling |
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168 | (13) |
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6.3.1.1 Plain-Milling Cutters |
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172 | (1) |
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6.3.1.2 Cutting Speed of Tool and Workpiece Feed |
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172 | (1) |
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6.3.1.3 Elements of Undeformed Chip |
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173 | (1) |
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6.3.1.4 Forces and Power in Milling |
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174 | (4) |
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6.3.1.5 Surface Roughness in Plain Milling |
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178 | (1) |
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179 | (1) |
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6.3.1.7 Factors Affecting the Cutting Forces |
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180 | (1) |
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181 | (1) |
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181 | (8) |
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6.3.2.1 Face-Milling Cutters |
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182 | (1) |
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6.3.2.2 Elements of Undeformed Chip |
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183 | (3) |
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6.3.2.3 Surface Roughness |
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186 | (2) |
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188 | (1) |
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188 | (1) |
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6.3.3 Selection of Milling Conditions |
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189 | (1) |
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190 | (15) |
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194 | (4) |
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6.4.2 Chip Formation in Broaching |
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198 | (1) |
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6.4.3 Broaching Force and Power |
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199 | (1) |
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200 | (1) |
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6.4.5 Accuracy and Surface Finish |
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201 | (1) |
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202 | (2) |
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204 | (1) |
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205 | (4) |
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205 | (1) |
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206 | (1) |
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207 | (1) |
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208 | (1) |
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209 | (2) |
Chapter 7 High-Speed Machining |
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211 | (16) |
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211 | (1) |
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211 | (1) |
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7.3 Chip Formation in HSM |
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212 | (1) |
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7.4 Characteristics of HSM |
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213 | (4) |
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7.5 Machining-Related Measurements |
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217 | (6) |
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217 | (2) |
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7.5.1.1 Dynamometers Based on Displacement Measurement |
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218 | (1) |
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7.5.1.2 Dynamometers Based on Strain Measurement |
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218 | (1) |
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7.5.1.3 Piezoelectric (Quartz) Dynamometers |
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219 | (1) |
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7.5.2 Vibration Measurements |
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219 | (1) |
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7.5.3 Temperature Measurements |
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220 | (3) |
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7.5.3.1 Thermocouple Techniques |
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220 | (2) |
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7.5.3.2 Infrared Techniques |
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222 | (1) |
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7.5.4 Tool Wear Measurements |
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223 | (1) |
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223 | (2) |
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225 | (1) |
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226 | (1) |
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226 | (1) |
Chapter 8 Machining by Abrasion |
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227 | (46) |
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227 | (3) |
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230 | (14) |
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230 | (10) |
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8.2.1.1 Abrasive Materials |
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230 | (2) |
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232 | (1) |
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232 | (1) |
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233 | (1) |
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233 | (1) |
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8.2.1.6 Grinding-Wheel Designation |
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234 | (1) |
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235 | (1) |
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8.2.1.8 Selection of Grinding Wheels |
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235 | (3) |
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238 | (1) |
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8.2.1.10 Truing and Dressing |
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238 | (2) |
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8.2.1.11 Temperature in Grinding |
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240 | (1) |
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240 | (2) |
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8.2.3 Economics of Grinding |
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242 | (2) |
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244 | (1) |
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244 | (9) |
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8.3.1 Elements of Undeformed Chip |
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244 | (3) |
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8.3.2 Grinding Forces, Power, and Removal Rate |
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247 | (1) |
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8.3.3 Factors Affecting the Grinding Forces |
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248 | (1) |
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248 | (2) |
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250 | (1) |
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8.3.6 Surface Grinding Operations |
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251 | (2) |
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8.3.6.1 Plain (Periphery) and Face Grinding with Reciprocating Feed |
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251 | (1) |
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8.3.6.2 Surface Grinding with a Rotating Table |
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252 | (1) |
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8.3.6.3 Creep-Feed Grinding |
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252 | (1) |
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253 | (15) |
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8.4.1 Elements of Undeformed Chip |
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253 | (2) |
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8.4.2 Forces, Power, and Removal Rate |
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255 | (1) |
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8.4.3 Factors Affecting the Grinding Forces |
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256 | (1) |
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8.4.4 Factors Affecting Surface Roughness |
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256 | (2) |
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258 | (2) |
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8.4.6 Cylindrical Grinding Operations |
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260 | (13) |
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8.4.6.1 External Cylindrical Grinding |
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260 | (3) |
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8.4.6.2 External Centerless Grinding |
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263 | (2) |
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8.4.6.3 Internal Cylindrical Grinding |
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265 | (1) |
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8.4.6.4 Internal Centerless Grinding |
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266 | (2) |
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8.5 Wheel Speed and Workpiece Feed |
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268 | (1) |
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268 | (2) |
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270 | (3) |
Chapter 9 Abrasive Finishing Processes |
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273 | (32) |
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273 | (1) |
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273 | (10) |
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276 | (2) |
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278 | (1) |
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9.2.3 Process Description |
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279 | (1) |
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9.2.4 Process Characteristics |
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280 | (3) |
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283 | (11) |
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285 | (3) |
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9.3.2 Mechanics of Lapping |
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288 | (2) |
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9.3.3 Process Characteristics |
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290 | (3) |
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293 | (1) |
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294 | (8) |
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9.4.1 Kinematics of Superfinishing |
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298 | (2) |
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9.4.2 Process Characteristics |
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300 | (2) |
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302 | (1) |
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302 | (1) |
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303 | (2) |
Chapter 10 Modern Abrasive Processes |
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305 | (28) |
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10.1 Ultrasonic Machining |
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305 | (16) |
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10.1.1 Mechanism of Material Removal |
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307 | (3) |
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310 | (2) |
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10.1.3 Factors Affecting Material Removal Rate |
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312 | (6) |
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10.1.4 Dimensional Accuracy |
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318 | (1) |
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318 | (2) |
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320 | (1) |
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10.2 Abrasive Jet Machining |
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321 | (6) |
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10.2.1 Material Removal Rate |
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322 | (4) |
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326 | (1) |
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10.3 Abrasive Water Jet Machining |
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327 | (6) |
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10.3.1 Process Characteristics |
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329 | (4) |
10.4 Abrasive Flow Machining |
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333 | (6) |
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336 | (2) |
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338 | (1) |
Chapter 11 Magnetic Field-Assisted Finishing Processes |
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339 | (12) |
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339 | (1) |
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11.2 Magnetic Abrasive Finishing |
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339 | (7) |
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11.2.1 Process Description |
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341 | (1) |
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11.2.2 Process Characteristics |
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342 | (9) |
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11.2.2.1 Material Removal Rate and Surface Finish |
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342 | (2) |
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344 | (2) |
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11.3 Magnetic Float Polishing |
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346 | (1) |
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11.4 Magnetorheological Finishing |
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347 | (1) |
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11.5 Magnetorheological Abrasive Flow Finishing |
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347 | (2) |
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349 | (2) |
Chapter 12 Mass Finishing Operations |
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351 | (18) |
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351 | (1) |
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351 | (4) |
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351 | (4) |
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355 | (1) |
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12.3 Mechanical Mass Finishing |
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355 | (7) |
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355 | (2) |
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12.3.2 Vibratory Finishing |
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357 | (1) |
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12.3.3 Centrifugal Barrel Finishing |
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358 | (1) |
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12.3.4 Centrifugal Disc Finishing |
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359 | (1) |
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360 | (2) |
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12.4 Electrochemical Mass Finishing |
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362 | (2) |
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12.4.1 Machining Principles |
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362 | (1) |
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12.4.2 Factors Affecting Material Removal |
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363 | (1) |
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364 | (1) |
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364 | (2) |
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366 | (3) |
Chapter 13 Machining by Electrochemical Erosion |
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369 | (28) |
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369 | (1) |
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369 | (2) |
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13.3 Advantages and Disadvantages of ECM |
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371 | (1) |
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371 | (1) |
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371 | (1) |
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13.4 Material Removal Rate by ECM |
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371 | (7) |
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378 | (1) |
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379 | (2) |
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13.7 Process Characteristics |
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381 | (2) |
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383 | (2) |
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385 | (5) |
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390 | (2) |
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392 | (1) |
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393 | (2) |
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395 | (2) |
Chapter 14 Machining by Thermal Erosion |
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397 | (38) |
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397 | (1) |
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14.2 Electrodischarge Machining |
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397 | (14) |
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14.2.1 Mechanism of Material Removal |
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397 | (5) |
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402 | (4) |
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14.2.3 Material Removal Rates |
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406 | (1) |
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407 | (1) |
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14.2.5 Heat-Affected Zone |
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408 | (1) |
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409 | (2) |
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14.3 Laser Beam Machining |
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411 | (7) |
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14.3.1 Material Removal Mechanism |
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412 | (3) |
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415 | (1) |
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415 | (3) |
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14.4 Electron Beam Machining |
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418 | (9) |
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14.4.1 Material Removal Process |
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419 | (2) |
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421 | (3) |
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424 | (3) |
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427 | (1) |
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14.6 Plasma Beam Machining |
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427 | (6) |
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14.6.1 Material Removal Rate |
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430 | (2) |
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432 | (1) |
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433 | (1) |
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434 | (1) |
Chapter 15 Hybrid Machining Processes |
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435 | (14) |
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435 | (1) |
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15.2 Hybrid Electrochemical Processes |
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435 | (5) |
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15.2.1 Electrochemical Grinding |
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435 | (3) |
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15.2.2 Electrochemical Honing |
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438 | (1) |
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15.2.3 Electrochemical Superfinishing |
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439 | (1) |
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15.2.4 Electrochemical Buffing |
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439 | (1) |
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15.2.5 Ultrasonic-Assisted Electrochemical Machining |
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440 | (1) |
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15.3 Hybrid Thermal Processes |
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440 | (7) |
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15.3.1 Electroerosion Dissolution Machining |
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441 | (2) |
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15.3.2 Abrasive Electrodischarge Grinding |
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443 | (1) |
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15.3.3 Abrasive Electrodischarge Machining |
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443 | (2) |
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15.3.4 EDM with Ultrasonic Assistance |
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445 | (1) |
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15.3.5 Electrochemical Discharge Grinding |
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446 | (1) |
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15.3.6 Brush Erosion Dissolution Mechanical Machining |
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446 | (1) |
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447 | (1) |
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448 | (1) |
Chapter 16 Micromachining |
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449 | (18) |
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449 | (1) |
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16.2 Conventional Micromachining |
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449 | (3) |
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16.2.1 Diamond Microturning |
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450 | (2) |
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452 | (1) |
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16.3 Abrasive Micromachining |
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452 | (3) |
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452 | (1) |
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16.3.2 Magnetic Abrasive Microfinishing |
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453 | (1) |
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16.3.3 Microsuperfinishing |
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454 | (1) |
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454 | (1) |
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16.3.5 Micro-Ultrasonic Machining |
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454 | (1) |
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16.4 Nonconventional Micromachining |
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455 | (10) |
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16.4.1 Micromachining by Thermal Erosion |
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455 | (5) |
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456 | (3) |
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16.4.1.2 Laser Micromachining |
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459 | (1) |
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16.4.2 Micromachining by Electrochemical Erosion |
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460 | (3) |
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16.4.3 Hybrid Micromachining Processes |
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463 | (10) |
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16.4.3.1 Chemical-Assisted Mechanical Polishing |
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463 | (1) |
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16.4.3.2 Mechanochemical Polishing |
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464 | (1) |
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16.4.3.3 Electrolytic In-process Dressing of Grinding Wheels |
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464 | (1) |
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465 | (2) |
Chapter 17 Machining Composite Materials |
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467 | (24) |
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467 | (1) |
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17.2 Reinforcing Materials |
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467 | (4) |
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471 | (1) |
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17.4 Machining of Composites |
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472 | (1) |
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473 | (6) |
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17.5.1 Cutting Particulate-Reinforced Composites |
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474 | (1) |
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17.5.2 Cutting Unidirectional Composites |
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474 | (4) |
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17.5.2.1 Sharp-Edged Tools |
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475 | (3) |
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17.5.2.2 Nose Radiused Tools |
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478 | (1) |
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17.5.3 Cutting Multidirectional Composites |
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478 | (1) |
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17.6 Traditional Machining Operations |
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479 | (7) |
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479 | (2) |
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481 | (3) |
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17.6.3 Milling and Trimming |
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484 | (1) |
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485 | (1) |
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17.7 Nontraditional Machining |
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486 | (3) |
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17.7.1 Abrasive Water Jet Machining |
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486 | (1) |
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17.7.2 Laser Beam Machining |
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487 | (1) |
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17.7.3 Electrodischarge Machining |
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488 | (1) |
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489 | (1) |
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489 | (1) |
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490 | (1) |
Chapter 18 Vibration-Assisted Machining |
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491 | (14) |
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491 | (1) |
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491 | (5) |
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491 | (3) |
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494 | (2) |
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496 | (1) |
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18.4 Vibration-Assisted Conventional Machining |
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497 | (4) |
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|
497 | (1) |
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498 | (1) |
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499 | (1) |
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|
500 | (1) |
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18.5 Nonconventional Vibration-Assisted Machining |
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501 | (3) |
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18.5.1 Electrodischarge Machining |
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501 | (1) |
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18.5.2 Electrochemical Machining |
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502 | (1) |
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18.5.3 Abrasive Waterjet Machining |
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|
503 | (1) |
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|
504 | (1) |
Chapter 19 Machinability |
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505 | (18) |
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505 | (1) |
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19.2 Conventional Machining |
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|
505 | (11) |
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19.2.1 Judging Machinability |
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|
505 | (2) |
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19.2.2 Relative Machinability |
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|
507 | (1) |
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19.2.3 Factors Affecting Machinability |
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508 | (3) |
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19.2.3.1 Condition of Work Material |
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509 | (1) |
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19.2.3.2 Physical Properties of Work Materials |
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510 | (1) |
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19.2.3.3 Machining Parameters |
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|
510 | (1) |
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19.2.4 Machinability of Engineering Materials |
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511 | (12) |
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19.2.4.1 Machinability of Steels and Alloy Steels |
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|
511 | (2) |
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19.2.4.2 Machinability of Cast Irons |
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513 | (1) |
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19.2.4.3 Machinability of Nonferrous Metals and Alloys |
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514 | (1) |
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19.2.4.4 Machinability of Nonmetallic Materials |
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|
515 | (1) |
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19.3 Nonconventional Machining |
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|
516 | (6) |
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|
522 | (1) |
Chapter 20 Machining Process Selection |
|
523 | (20) |
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|
523 | (1) |
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20.2 Factors Affecting Process Selection |
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|
523 | (18) |
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|
523 | (2) |
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|
525 | (1) |
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20.2.3 Dimensional and Geometric Features |
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|
525 | (2) |
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527 | (5) |
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532 | (1) |
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20.2.6 Production Quantity |
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533 | (4) |
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|
537 | (1) |
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20.2.8 Environmental Impacts |
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537 | (3) |
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20.2.9 Process and Machine Capability |
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|
540 | (1) |
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|
541 | (2) |
References |
|
543 | (4) |
Index |
|
547 | |