Manufacturing Processes

8.

Subtractive Processes: Machining

8.1.

Metal Cutting Theory

8.1.1.

Chip Formation Mechanics

8.1.1.1.

Orthogonal Cutting Model

8.1.1.2.

Oblique Cutting

8.1.1.3.

Shear Plane Theory

8.1.2.

8.1.2.1.

Continuous Chips

8.1.2.2.

Built-up Edge Chips

8.1.2.3.

Discontinuous Chips

8.1.2.4.

8.1.3.

8.1.3.1.

Primary Cutting Force

8.1.3.2.

8.1.3.3.

8.1.3.4.

Merchant's Circle Analysis

8.1.4.

Cutting Temperature

8.1.4.1.

Heat Generation Sources

8.1.4.2.

Temperature Distribution

8.1.4.3.

Effects on Tool Life

8.1.5.

Tool Wear Mechanisms

8.1.5.1.

8.1.5.2.

8.1.5.3.

8.1.5.4.

8.1.5.5.

8.1.6.

Tool Life Relationships

8.1.6.1.

Taylor's Tool Life Equation

8.1.6.2.

Extended Tool Life Models

8.1.6.3.

Tool Life Testing

8.1.7.

Cutting Tool Materials

8.1.7.1.

High Speed Steels

8.1.7.2.

8.1.7.3.

8.1.7.4.

Cubic Boron Nitride

8.1.7.5.

8.1.7.6.

8.1.8.

8.1.8.1.

Functions of Cutting Fluids

8.1.8.2.

Types of Cutting Fluids

8.1.8.3.

Application Methods

8.1.8.4.

Environmental Considerations

8.2.

Turning Operations

8.2.1.

Lathe Machine Components

8.2.1.1.

Headstock Assembly

8.2.1.2.

Tailstock Assembly

8.2.1.3.

Carriage and Cross Slide

8.2.1.4.

8.2.1.5.

Feed Mechanisms

8.2.2.

Turning Operations

8.2.2.1.

Straight Turning

8.2.2.2.

8.2.2.2.1.

Compound Rest Method

8.2.2.2.2.

Tailstock Offset Method

8.2.2.2.3.

Taper Attachment Method

8.2.2.3.

Facing Operations

8.2.2.4.

Parting and Grooving

8.2.2.5.

8.2.2.5.1.

8.2.2.5.2.

8.2.2.5.3.

8.2.2.6.

8.2.3.

8.2.3.1.

Single Point Tools

8.2.3.2.

8.2.3.2.1.

8.2.3.2.2.

Clearance Angles

8.2.3.2.3.

Cutting Edge Angles

8.2.3.3.

Tool Holders and Inserts

8.2.4.

Turning Parameters

8.2.4.1.

8.2.4.2.

8.2.4.3.

8.2.4.4.

Material Removal Rate

8.3.

Drilling and Related Operations

8.3.1.

Drilling Process

8.3.1.1.

Drill Bit Geometry

8.3.1.1.1.

8.3.1.1.2.

8.3.1.1.3.

Lip Relief Angle

8.3.1.2.

Drilling Forces and Torque

8.3.1.3.

Chip Evacuation

8.3.2.

Types of Drills

8.3.2.1.

8.3.2.2.

8.3.2.3.

8.3.2.4.

8.3.2.5.

8.3.3.

Drilling Machines

8.3.3.1.

Bench Drill Press

8.3.3.2.

Floor Drill Press

8.3.3.3.

Radial Drill Press

8.3.3.4.

Multiple Spindle Drills

8.3.4.

Related Operations

8.3.4.1.

8.3.4.1.1.

8.3.4.1.2.

Machine Reamers

8.3.4.1.3.

Adjustable Reamers

8.3.4.2.

8.3.4.2.1.

8.3.4.2.2.

8.3.4.2.3.

Precision Boring

8.3.4.3.

8.3.4.3.1.

8.3.4.3.2.

Machine Tapping

8.3.4.3.3.

8.3.4.4.

Countersinking and Counterboring

8.3.5.

Drilling Problems and Solutions

8.3.5.1.

Drill Wandering

8.3.5.2.

8.3.5.3.

8.3.5.4.

Poor Surface Finish

8.4.

Milling Operations

8.4.1.

Milling Machine Types

8.4.1.1.

Horizontal Milling Machines

8.4.1.2.

Vertical Milling Machines

8.4.1.3.

Universal Milling Machines

8.4.1.4.

CNC Milling Centers

8.4.2.

Milling Cutters

8.4.2.1.

8.4.2.2.

8.4.2.3.

8.4.2.4.

8.4.2.5.

8.4.2.6.

8.4.3.

Milling Operations

8.4.3.1.

8.4.3.2.

Peripheral Milling

8.4.3.3.

8.4.3.4.

8.4.3.5.

8.4.3.6.

8.4.3.7.

8.4.4.

Milling Parameters

8.4.4.1.

8.4.4.2.

8.4.4.3.

Axial and Radial Depth of Cut

8.4.4.4.

Climb vs Conventional Milling

8.4.5.

Workholding in Milling

8.4.5.1.

8.4.5.2.

Clamps and Fixtures

8.4.5.3.

8.4.5.4.

8.5.

Machining Centers and CNC

8.5.1.

Numerical Control Fundamentals

8.5.1.1.

Point-to-Point Control

8.5.1.2.

Continuous Path Control

8.5.1.3.

Coordinate Systems

8.5.1.4.

Interpolation Methods

8.5.2.

CNC Machine Components

8.5.2.1.

Machine Control Unit

8.5.2.2.

8.5.2.3.

Feedback Systems

8.5.2.4.

8.5.3.

CNC Programming

8.5.3.1.

8.5.3.1.1.

Preparatory Functions

8.5.3.1.2.

Motion Commands

8.5.3.1.3.

8.5.3.2.

8.5.3.2.1.

Miscellaneous Functions

8.5.3.2.2.

Machine Control Commands

8.5.3.3.

Programming Methods

8.5.3.3.1.

Manual Programming

8.5.3.3.2.

Computer-Assisted Programming

8.5.3.3.3.

8.5.4.

Machining Centers

8.5.4.1.

Vertical Machining Centers

8.5.4.2.

Horizontal Machining Centers

8.5.4.3.

Five-Axis Machining Centers

8.5.4.4.

Multi-Tasking Machines

8.5.5.

Automated Systems

8.5.5.1.

Automatic Tool Changers

8.5.5.2.

8.5.5.3.

Flexible Manufacturing Cells

8.6.

Abrasive Machining

8.6.1.

Grinding Fundamentals

8.6.1.1.

Abrasive Grains

8.6.1.2.

Bonding Materials

8.6.1.3.

Grinding Wheel Structure

8.6.1.4.

Wheel Marking System

8.6.2.

Grinding Processes

8.6.2.1.

Surface Grinding

8.6.2.1.1.

Horizontal Spindle Surface Grinding

8.6.2.1.2.

Vertical Spindle Surface Grinding

8.6.2.2.

Cylindrical Grinding

8.6.2.2.1.

External Cylindrical Grinding

8.6.2.2.2.

Internal Cylindrical Grinding

8.6.2.2.3.

Centerless Grinding

8.6.2.3.

Tool and Cutter Grinding

8.6.2.4.

Creep Feed Grinding

8.6.3.

Grinding Parameters

8.6.3.1.

8.6.3.2.

8.6.3.3.

8.6.3.4.

8.6.4.

Grinding Fluids

8.6.5.

Wheel Dressing and Truing

8.6.6.

Other Abrasive Processes

8.6.6.1.

8.6.6.1.1.

Cylinder Honing

8.6.6.1.2.

8.6.6.2.

8.6.6.2.1.

8.6.6.2.2.

Machine Lapping

8.6.6.3.

8.6.6.4.

Polishing and Buffing

8.6.6.5.

Abrasive Flow Machining

8.7.

Nontraditional Machining

8.7.1.

Electrical Discharge Machining

8.7.1.1.

EDM Process Principles

8.7.1.2.

Die Sinking EDM

8.7.1.2.1.

Electrode Materials

8.7.1.2.2.

Dielectric Fluids

8.7.1.2.3.

Process Parameters

8.7.1.3.

8.7.1.3.1.

8.7.1.3.2.

Wire Feeding Systems

8.7.1.3.3.

Cutting Strategies

8.7.2.

Electrochemical Machining

8.7.2.1.

ECM Process Principles

8.7.2.2.

8.7.2.3.

8.7.2.4.

Process Parameters

8.7.3.

Laser Beam Machining

8.7.3.1.

8.7.3.2.

Process Parameters

8.7.3.3.

Safety Considerations

8.7.4.

Electron Beam Machining

8.7.5.

Water Jet Cutting

8.7.5.1.

8.7.5.2.

Abrasive Water Jet

8.7.5.3.

Cutting Parameters

8.7.6.

Ultrasonic Machining

8.7.6.1.

Process Principles

8.7.6.2.

Abrasive Slurries

8.7.6.3.

8.7.7.

Chemical Machining

8.7.7.1.

Chemical Milling

8.7.7.2.

Photochemical Machining

8.7.7.3.

Etchants and Maskants

8.7.8.

Plasma Arc Machining

8.7.9.

Ion Beam Machining

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9. Joining and Assembly Processes