Conditions in Milling
11.4.4Milling Cutters
11.4.5Milling Machines
11.5Sawing
11.5.1Types of Sawing
11.5.2Saw Blades
11.6Planing and Shaping
11.6.1Planing and Planers
11.6.2Shaping and Shapers
11.6.3Cutting Conditions
11.7Broaching
11.7.1Broaches
11.7.2Broaching Machines
11.8Gear Manufacturing
11.8.1Gear Terminology and Definitions
11.8.2Methods of Manufacturing Gears
11.8.3Gear Finishing Processes
Chapter 12Abrasive Machining Processes
12.1Introduction
12.2Abrasives
12.2.1Abrasive Grain Size and Geometry
12.3Grinding
12.3.1Grinding Wheels
12.3.2Analysis of the Grinding Process
12.3.3Grinding Operations and Machines
12.4Finishing Operations
12.4.1Honing
12.4.2Lapping
12.4.3Superfinishing
12.4.4Polishing and Buffing
Chapter 13Nontraditional Machining Processes
13.1Introduction
13.2Mechanical Energy Processes
13.2.1Ultrasonic Machining
13.2.2Water-Jet Cutting
13.3Electrochemical Machining Processes
13.3.1Electrochemical Machining
13.3.2Electrochemical Grinding
13.4Thermal Energy Processes
13.4.1Electric Discharge Processes
13.4.2Laser Beam Machining
13.4.3Electron Beam Machining
13.5Chemical Machining
13.5.1Chemical Milling
Index
The study of manufacturing engineering is an important discipline in any industrial society, and within that discipline one of the more important subjects is manufacturing processes. This book is intended to treat one broad and challenging part of this subject—metal shaping processes. It is a comprehensive text written mainly for students in mechanical, industrial, and manufacturing engineering programs at both the associate and bachelor degree levels. The fundamentals of metal shaping processes and their relevant applications are presented step-by-step so that the reader can clearly assess the capabilities, limitations, and potentialities of these processes and their competitive aspects. The text, as well as the numerous formulas and illustrations in each chapter, clearly shows that shaping processes, as a part of manufacturing engineering, constitute a complex and interdisciplinary subject. The topics are organized and presented in such a manner that they motivate and challenge students to develop technically and economically viable solutions to a wide variety of questions and problems, including product design.
The field of mechanical engineering and manufacturing technology continues to advance rapidly, transcending disciplines and driving economic growth. This challenging field continues to incorporate new concepts at an increasing rate, making manufacturing a dynamic and exciting field of study. In preparing this book my most important goal was to provide a comprehensive state-of-the-art textbook on the most common metal shaping processes; an equally important aim was to motivate and challenge students to understand and later, perhaps, to work with this common manufacturing process.
The book is organized into four parts with thirteen chapters. The first part of the book covers casting, molding, and other processes in which the starting material is a heated liquid. The discussion is divided into three chapters: The fundamentals of metal casting processes, metal casting processes, and metal casting design and materials.
The second part of the book deals with basic particulate processing, these in which the starting materials are metal powders. The powder metallurgy of the various metals is discussed as one unit.
The third part discusses the most commonly used metal deformation processes, in which the starting materials are solid. This section is divided into five chapters: The fundamentals of metal forming, rolling, forging, extrusion and drawing, and sheet metal working.
The fourth part of the book discusses the most commonly used metal removal processes, those in which the starting materials are likewise solid. This part of the book is divided into four chapters: The fundamentals of metal machining, machining processes, abrasive machining processes, and nontraditional machining processes.
Although the book provides many calculations, illustrations, and tables, it should be evident that detailed analytical mathematical transformations are not included; however, the final formulas derived from them (which are necessary in practical applications) are included.
Measurements are given in both ISO and U.S. unit systems. At the end of each chapter, review questions are given that allow students to review chapter contents in a quick and enjoyable fashion.
By reading and studying this book, my hope is that students will be introduced to an academic subject that is as exciting, challenging, and as important as any other engineering and technology discipline; professionals will also find this book a very effective tool and reference.
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