Conventions Used in This Book |
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xxvii | |
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xix | |
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Introduction to the International (SI) System of Units |
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xix | |
Chapter 1 Machine Tools and Machining Operations |
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1 | (68) |
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1 | (1) |
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1.2 Generating Motions of Machine Tools |
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2 | (3) |
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1.3 Machines Using Single-Point Tools |
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5 | (19) |
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1.3.1 Engine Lathe (Center Lathe) |
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5 | (2) |
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7 | (3) |
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1.3.3 Typical Lathe Operations |
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10 | (4) |
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1.3.4 Work and Tool Holding in an Engine Lathe |
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14 | (2) |
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1.3.5 Other Types of Lathes |
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16 | (2) |
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1.3.6 Vertical-Boring Machine (Vertical Borer) |
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18 | (1) |
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1.3.7 Horizontal-Boring Machine (Horizontal Borer) |
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19 | (1) |
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1.3.8 Shaping Machine (Shaper) |
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20 | (3) |
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1.3.9 Planing Machine (Planer) |
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23 | (1) |
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1.4 Machines Using Multipoint Tools |
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24 | (21) |
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24 | (1) |
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1.4.2 Drilling Machine (Drill Press) |
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25 | (6) |
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1.4.3 Horizontal-Milling Machine (Horizontal Miller) |
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31 | (5) |
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1.4.4 Vertical-Milling Machine (Vertical Miller) |
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36 | (5) |
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1.4.5 Broaching Machine (Broacher) |
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41 | (3) |
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44 | (1) |
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1.5 Machines Using Abrasive Wheels |
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45 | (12) |
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45 | (1) |
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1.5.2 Horizontal-Spindle Surface-Grinding Machine (Horizontal-Spindle Surface Grinder) |
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46 | (3) |
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1.5.3 Vertical-Spindle Surface-Grinding Machine (Vertical-Spindle Surface Grinder) |
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49 | (3) |
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1.5.4 Cylindrical-Grinding Machine (Cylindrical Grinder) |
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52 | (1) |
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1.5.5 Internal-Grinding Machine (Internal Grinder) |
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53 | (2) |
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1.5.6 Centerless Grinding Machines |
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55 | (2) |
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1.6 Summary of Machine Tool Characteristics and Machining Equations |
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57 | (7) |
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64 | (4) |
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68 | (1) |
Chapter 2 Mechanics of Metal Cutting |
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69 | (52) |
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69 | (2) |
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2.2 Terms and Definitions |
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71 | (2) |
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73 | (5) |
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74 | (2) |
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2.3.2 Continuous Chip with Built-up Edge |
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76 | (1) |
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76 | (1) |
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2.3.4 Other Types of Chip Formation |
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77 | (1) |
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2.4 The Forces Acting on the Cutting Tool and Their Measurement |
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78 | (3) |
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2.5 Specific Cutting Energy |
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81 | (1) |
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2.6 Plowing Force and the "Size Effect" |
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82 | (2) |
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2.7 The Apparent Mean Shear Strength of the Work Material |
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84 | (3) |
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87 | (10) |
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2.8.1 Theory of Ernst and Merchant |
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88 | (4) |
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2.8.2 Theory of Lee and Shaffer |
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92 | (2) |
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2.8.3 Experimental Evidence |
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94 | (3) |
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2.9 Friction in Metal Cutting |
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97 | (3) |
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2.10 Analytical Modeling of Machining Operations |
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100 | (14) |
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2.10.1 Mechanistic Modeling of Machining |
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101 | (1) |
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2.10.2 Slip Line Field Analysis |
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102 | (2) |
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2.10.3 Predictive Models for Orthogonal Cutting |
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104 | (6) |
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2.10.4 Finite Element Analysis |
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110 | (2) |
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2.10.5 Modeling of Material Properties |
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112 | (2) |
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114 | (3) |
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117 | (4) |
Chapter 3 Temperatures in Metal Cutting |
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121 | (20) |
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3.1 Heat Generation in Metal Cutting |
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121 | (2) |
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3.2 Heat Transfer in a Moving Material |
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123 | (1) |
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3.3 Temperature Distribution in Metal Cutting |
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124 | (10) |
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3.3.1 Temperatures in the Primary Deformation Zone |
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126 | (1) |
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3.3.2 Temperatures in the Secondary Deformation Zone |
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127 | (1) |
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128 | (5) |
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3.3.4 Effect of Cutting Speed on Temperatures |
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133 | (1) |
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3.3.5 Prediction of Temperature Distributions in Machining |
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133 | (1) |
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3.4 The Measurement of Cutting Temperatures |
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134 | (3) |
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3.4.1 Work-Tool Thermocouple |
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134 | (1) |
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3.4.2 Direct Thermocouple Measurements |
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135 | (1) |
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136 | (1) |
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3.4.4 Hardness and Microstructure Changes in Steel Tools |
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137 | (1) |
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137 | (2) |
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139 | (2) |
Chapter 4 Tool Life and Tool Materials |
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141 | (34) |
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141 | (1) |
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4.2 Progressive Tool Wear |
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141 | (1) |
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4.3 Forms of Wear in Metal Cutting |
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142 | (12) |
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142 | (1) |
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143 | (1) |
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143 | (1) |
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4.3.4 Common Criteria for High-Speed Steel or Ceramic Tools |
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144 | (1) |
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4.3.5 Common Criteria for Sintered-Carbide Tools |
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145 | (1) |
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145 | (3) |
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4.3.7 Premature Tool Failure |
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148 | (1) |
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4.3.8 The Effect of a Built-up Edge |
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148 | (1) |
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4.3.9 The Effect of Tool Angles |
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149 | (2) |
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4.3.10 The Effect of Speed and Feed on Cratering and Built-up-Edge Formation |
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151 | (1) |
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4.3.11 Tool Damage Models |
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152 | (2) |
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154 | (10) |
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4.4.1 Basic Requirements of Tool Materials |
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154 | (1) |
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4.4.2 Major Classes of Tool Materials |
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155 | (2) |
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157 | (1) |
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158 | (1) |
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4.4.5 Cemented Carbide Tools |
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158 | (2) |
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160 | (1) |
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160 | (1) |
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4.4.8 Polycrystalline Tools |
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161 | (1) |
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162 | (2) |
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164 | (1) |
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165 | (3) |
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4.6.1 Tool Wear and Machinability Testing |
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166 | (1) |
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4.6.2 Factors Affecting the Machinability of Metals |
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167 | (1) |
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168 | (3) |
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171 | (1) |
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172 | (1) |
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173 | (2) |
Chapter 5 Cutting Fluids and Surface Roughness |
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175 | (36) |
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175 | (1) |
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5.2 The Action of Coolants |
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176 | (3) |
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5.3 The Action of Lubricants |
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179 | (4) |
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5.3.1 Boundary Lubrication |
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179 | (1) |
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5.3.2 Lubrication in Metal Cutting |
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180 | (1) |
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5.3.3 Characteristics of an Efficient Lubricant in Metal Cutting |
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181 | (2) |
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5.4 Application of Cutting Fluids |
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183 | (3) |
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185 | (1) |
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185 | (1) |
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185 | (1) |
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185 | (1) |
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5.4.5 Through the Tool Application |
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186 | (1) |
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5.5 Cutting Fluid Maintenance |
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186 | (1) |
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5.6 Environmental Considerations |
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187 | (1) |
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5.7 Disposal of Cutting Fluids |
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187 | (2) |
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5.8 Dry Cutting and Minimum Quantity Lubrication |
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189 | (3) |
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192 | (8) |
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5.9.1 Ideal Surface Roughness |
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192 | (3) |
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5.9.2 Natural Surface Roughness |
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195 | (3) |
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5.9.3 Measurement of Surface Roughness |
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198 | (2) |
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5.10 Tool Geometries for Improved Surface Finish |
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200 | (1) |
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5.11 Burr Formation in Machining |
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200 | (5) |
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205 | (3) |
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208 | (3) |
Chapter 6 Economics of Metal-Cutting Operations |
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211 | (38) |
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211 | (1) |
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212 | (1) |
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6.3 Choice of Cutting Speed |
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213 | (5) |
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6.4 Tool Life for Minimum Cost and Minimum Production Time |
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218 | (501) |
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6.5 Estimation of Factors Needed to Determine Optimum Conditions |
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719 | |
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6.6 Example of a Constant-Cutting-Speed Operation |
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221 | (552) |
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6.7 Machining at Maximum Efficiency |
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773 | |
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225 | (503) |
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6.9 Operations with Interrupted Cuts |
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728 | |
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6.10 Economics of Various Tool Materials and Tool Designs |
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230 | (4) |
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6.11 Machinability Data Systems |
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234 | (501) |
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234 | (500) |
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6.11.2 Mathematical Model Systems |
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734 | (1) |
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6.12 Limitations of Available Machinability Data |
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735 | |
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6.12.1 Feed and Depth of Cut in Turning |
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735 | |
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6.12.2 Cutting Speed, Depth of Cut, and Hardness in Turning |
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235 | (3) |
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6.12.3 Estimation of Recommended Feed and Speed |
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238 | (1) |
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238 | (1) |
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6.12.4 Relationships for Other Turning Processes |
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239 | (4) |
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6.12.5 Relationships for Other Machining Processes |
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243 | (1) |
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6.12.6 Accuracy of Relationships for Recommended Cutting Conditions |
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243 | (1) |
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243 | (4) |
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247 | (2) |
Chapter 7 Nomenclature of Cutting Tools |
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249 | (18) |
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249 | (2) |
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7.2 Systems of Cutting-Tool Nomenclature |
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251 | (4) |
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7.2.1 British Maximum-Rake System |
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251 | (1) |
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7.2.2 American Standards Association System |
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252 | (1) |
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253 | (2) |
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7.3 International Standard |
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255 | (10) |
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7.3.1 Tool-in-Hand and Tool-in-Use Systems |
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255 | (4) |
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259 | (1) |
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7.3.3 Mathematical Relationships Between Tool and Working Systems |
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260 | (2) |
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262 | (1) |
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7.3.5 Calculation of Tool Angles from Working Angles |
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263 | (2) |
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265 | (1) |
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265 | (2) |
Chapter 8 Chip Control |
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267 | (16) |
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267 | (1) |
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267 | (7) |
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8.3 Prediction of Radius of Chip Curvature |
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274 | (3) |
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8.4 Prediction of Chip Breaking Performance |
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277 | (3) |
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8.5 Tool Wear During Chip Breaking |
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280 | (1) |
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280 | (2) |
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282 | (1) |
Chapter 9 Machine Tool Vibrations |
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283 | (38) |
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283 | (1) |
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284 | (8) |
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9.2.1 Single-Degree-of-Freedom System |
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284 | (5) |
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289 | (3) |
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9.3 Self-Excited Vibrations (Chatter) |
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292 | (13) |
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9.3.1 Interaction of the Cutting Process and Machine Structure |
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292 | (4) |
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9.3.1.1 Regenerative Instability |
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294 | (1) |
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9.3.1.2 Mode-Coupling Instability |
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294 | (2) |
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296 | (1) |
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9.3.3 Analysis of Machine Tool Chatter |
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297 | (14) |
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297 | (2) |
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9.3.3.2 Machine Structure |
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299 | (2) |
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9.3.3.3 Stability Analysis |
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301 | (1) |
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9.3.3.4 Modification for Multiedge Cutting Operations |
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302 | (1) |
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303 | (2) |
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9.4 Determination of Frequency Response Loci |
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305 | (5) |
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9.5 Dynamic Acceptance Tests for Machine Tools |
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310 | (1) |
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9.6 Improving Machine Tool Stability |
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311 | (5) |
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9.6.1 Structural Alterations |
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311 | (1) |
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9.6.2 Vibration Absorbers |
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312 | (1) |
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9.6.3 Modification of the Regenerative Effect |
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312 | (3) |
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9.6.3.1 Variable-Pitch Milling Cutters |
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312 | (3) |
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9.6.3.2 Superimposed Speed Variation |
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315 | (1) |
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9.6.4 Active Force Control |
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315 | (1) |
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316 | (3) |
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319 | (2) |
Chapter 10 Grinding |
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321 | (38) |
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321 | (1) |
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321 | (8) |
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323 | (1) |
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324 | (1) |
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324 | (1) |
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325 | (1) |
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10.2.5 Designation of Grinding Wheels |
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325 | (4) |
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10.3 Effect of Grinding Conditions on Wheel Behavior |
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329 | (2) |
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10.4 Determination of the Density of Active Grains |
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331 | (1) |
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10.5 Testing of Grinding Wheels |
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331 | (1) |
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10.6 Dressing and Truing of Grinding Wheels |
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332 | (1) |
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10.7 Analysis of the Grinding Process |
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333 | (12) |
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10.7.1 Specific Cutting Energy for Grinding Processes |
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337 | (1) |
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10.7.2 Cylindrical Grinding Cycles |
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338 | (2) |
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10.7.3 Surface Grinding Cycles |
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340 | (1) |
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10.7.4 Equivalent Diameters of Grinding Wheels |
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340 | (2) |
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10.7.5 Metal Removal Parameter for Easy-to-Grind Materials |
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342 | (2) |
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344 | (1) |
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10.7.7 Metal Removal Parameter for Difficult-to-Grind Materials |
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345 | (1) |
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10.8 Thermal Effects in Grinding |
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345 | (3) |
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10.9 Cutting Fluids in Grinding |
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348 | (2) |
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10.9.1 General Discussion |
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348 | (1) |
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10.9.2 Application of Grinding Fluids |
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348 | (2) |
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10.10 Grinding-Wheel Wear |
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350 | (1) |
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10.11 Nonconventional Grinding Operations |
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351 | (3) |
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10.11.1 High-Speed Grinding |
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351 | (1) |
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10.11.2 Creep Feed Grinding |
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352 | (2) |
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10.11.3 Low-Stress Grinding |
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354 | (1) |
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354 | (2) |
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356 | (3) |
Chapter 11 Manufacturing Systems and Automation |
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359 | (42) |
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359 | (1) |
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359 | (1) |
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11.2.1 Mass or Continuous Production |
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360 | (1) |
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11.2.2 Large-Batch Production |
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360 | (1) |
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11.2.3 Small-Batch Production |
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360 | (1) |
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11.3 Types of Facilities Layout |
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360 | (2) |
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11.3.1 Functional or Process Layout |
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360 | (2) |
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362 | (1) |
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11.3.3 Group or Cellular Layout |
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362 | (1) |
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362 | (2) |
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363 | (1) |
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11.4.2 Programmable Automation |
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363 | (1) |
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11.4.2.1 Program Sequence Control |
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363 | (1) |
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11.4.2.2 Numerical Control |
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364 | (1) |
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364 | (5) |
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11.5.1 Economics of Transfer Machines |
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366 | (2) |
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368 | (1) |
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369 | (12) |
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11.6.1 Planning for Multi-spindle Automatic Lathes |
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370 | (10) |
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11.6.1.1 Process Plan Optimization |
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377 | (3) |
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11.6.2 Economics of Automatic Machines |
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380 | (1) |
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381 | (1) |
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11.7 Numerically Controlled (NC) Machine Tools |
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381 | (7) |
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11.7.1 Main Features of NC Systems |
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381 | (4) |
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11.7.1.1 Program of Instruction |
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381 | (2) |
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11.7.1.2 Machine Tool Controller |
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383 | (1) |
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384 | (1) |
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385 | (2) |
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11.7.2.1 Point-to-Point or Positional Control |
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385 | (1) |
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11.7.2.2 Straight-Line or Linear Control |
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386 | (1) |
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11.7.2.3 Continuous Path or Contouring Control |
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386 | (1) |
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11.7.3 Computers in Numerical Control |
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387 | (1) |
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11.7.4 Economics of Numerically Controlled Machines |
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387 | (1) |
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388 | (1) |
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11.8 Comparison of the Economics of Various Automation Systems |
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388 | (1) |
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11.9 Handling of Components in Batch Production |
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389 | (1) |
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11.10 Flexible Manufacturing Systems |
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390 | (9) |
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11.10.1 Machine Tools in FMSs |
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395 | (2) |
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11.10.2 Work Handling for FMSs |
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397 | (1) |
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397 | (2) |
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399 | (1) |
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11.10.5 Pallets and Fixtures for FMSs |
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399 | (1) |
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399 | (1) |
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400 | (1) |
Chapter 12 Computer-Aided Manufacturing |
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401 | (38) |
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401 | (1) |
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401 | (2) |
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12.3 Process-Planning Tasks |
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403 | (3) |
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12.4 Computer-Aided Process Planning |
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406 | (6) |
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12.5 Processing of NC Programs |
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412 | (3) |
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12.6 Manual Programming of NC Machines |
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415 | (8) |
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12.6.1 Fixed or Canned Cycles |
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420 | (1) |
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12.6.2 Tool Path Coordinates |
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421 | (2) |
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12.7 Computer-Aided NC Processing |
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423 | (2) |
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12.8 Numerical Control Processing Languages |
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425 | (2) |
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12.8.1 Input Information Level |
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425 | (1) |
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425 | (1) |
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426 | (1) |
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426 | (1) |
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12.8.2 Similarity of Language Structure |
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426 | (1) |
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12.8.2.1 Free-Format Languages |
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426 | (1) |
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12.8.2.2 Fixed-Format Languages |
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426 | (1) |
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12.9 NC Programming Using APT-Based Languages |
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427 | (7) |
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12.9.1 Language Structure |
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427 | (1) |
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12.9.1.1 Geometric Statements |
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427 | (1) |
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428 | (3) |
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12.9.3 Auxiliary Statements |
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431 | (1) |
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12.9.4 Programming Example in APT |
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431 | (3) |
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12.10 Graphics-Based NC Processing Systems |
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434 | (3) |
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437 | (2) |
Chapter 13 Design for Machining |
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439 | (66) |
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439 | (1) |
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440 | (1) |
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13.3 Choice of Work Material |
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440 | (2) |
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13.4 Shape of Work Material |
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442 | (2) |
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444 | (21) |
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444 | (9) |
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13.5.2 Rotational Components [ (L/D) less than or equal to 0.5] 445 |
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13.5.3 Rotational Components [ 0.5 less than (L/D) less than or equal to 3] 452 |
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13.5.4 Rotational Components [ (L/D > 31 |
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453 | (9) |
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13.5.5 Nonrotational Components [ (A/B) less than or equal to 3, (A/C) > or equal to 4] 458 |
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13.5.6 Nonrotational Components [ (A/B) > 3] |
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462 | (3) |
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13.5.7 Nonrotational Components [ (A/B) less than 3, (A/C) less than 4] 462 |
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13.6 Assembly of Components |
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465 | (1) |
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13.7 Accuracy and Surface Finish |
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466 | (5) |
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13.8 Summary of Design Guidelines |
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471 | (3) |
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472 | (1) |
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|
472 | (1) |
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|
472 | (2) |
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|
472 | (1) |
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13.8.3.2 Rotational Components |
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|
473 | (1) |
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13.8.3.3 Nonrotational Components |
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|
473 | (1) |
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|
474 | (1) |
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13.8.5 Accuracy and Surface Finish |
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|
474 | (1) |
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13.9 Cost Estimating for Machined Components |
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|
474 | (27) |
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|
475 | (1) |
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13.9.2 Machine Loading and Unloading |
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|
475 | (1) |
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13.9.3 Other Nonproductive Costs |
|
|
476 | (1) |
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13.9.4 Handling between Machines |
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|
476 | (2) |
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|
478 | (1) |
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|
478 | (2) |
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13.9.7 Tool Replacement Costs |
|
|
480 | (2) |
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|
482 | (3) |
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|
485 | (3) |
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|
488 | (1) |
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13.9.11 Allowance for Grinding Wheel Wear |
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|
488 | (3) |
|
|
490 | (1) |
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13.9.12 Allowance for Spark-Out |
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|
491 | (1) |
|
|
491 | (2) |
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13.9.14 Machining Cost Estimating Worksheet |
|
|
493 | (1) |
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|
493 | (1) |
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13.9.15 Approximate Cost Models for Machined Components |
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|
494 | (7) |
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|
501 | (2) |
|
|
503 | (2) |
Chapter 14 Nonconventional Machining Processes |
|
505 | (48) |
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|
505 | (1) |
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14.2 Range of Nonconventional Machining Processes |
|
|
506 | (1) |
|
14.3 Ultrasonic Machining |
|
|
506 | (5) |
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|
509 | (1) |
|
14.3.1.1 Piezoelectric Transducers |
|
|
509 | (1) |
|
14.3.1.2 Magnetostrictive Transducers |
|
|
509 | (1) |
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14.3.2 Transformer and Tool Holder |
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|
509 | (1) |
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|
510 | (1) |
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|
510 | (1) |
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|
511 | (1) |
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|
511 | (3) |
|
14.4.1 General Discussion |
|
|
511 | (1) |
|
|
512 | (2) |
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14.5 Abrasive-Jet Machining |
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|
514 | (2) |
|
14.5.1 General Discussion |
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|
514 | (2) |
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|
516 | (1) |
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|
516 | (2) |
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|
518 | (1) |
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|
518 | (1) |
|
14.7 Electrochemical Machining |
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|
518 | (6) |
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14.7.1 Metal Removal Rates |
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|
520 | (1) |
|
14.7.2 Nature of the Machine Surface |
|
|
521 | (1) |
|
14.7.3 Effect of Tool Feed Speed and Supply Voltage on Accuracy |
|
|
521 | (2) |
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14.7.4 Tools for Electrochemical Machining |
|
|
523 | (1) |
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|
523 | (1) |
|
14.8 Electrolytic Grinding |
|
|
524 | (1) |
|
14.9 Electrical-Discharge Machining |
|
|
525 | (6) |
|
14.9.1 Tool Materials and Tool Wear |
|
|
527 | (2) |
|
|
529 | (1) |
|
14.9.3 Process Parameters |
|
|
529 | (2) |
|
|
531 | (1) |
|
14.10 Wire Electrical-Discharge Machining |
|
|
531 | (3) |
|
14.11 Laser-Beam Machining |
|
|
534 | (7) |
|
|
535 | (1) |
|
14.11.2 Percussion Drilling of Small Holes |
|
|
535 | (1) |
|
14.11.3 Trepanning or Cutting Operations |
|
|
535 | (3) |
|
|
538 | (3) |
|
14.12 Electron-Beam Machining |
|
|
541 | (2) |
|
|
543 | (2) |
|
14.13.1 General Discussion |
|
|
543 | (1) |
|
|
543 | (2) |
|
14.14 Comparative Performance of Cutting Processes |
|
|
545 | (2) |
|
|
547 | (3) |
|
|
550 | (3) |
Nomenclature |
|
553 | (10) |
Index |
|
563 | |