El-Hofy - Fundamentals of machining processes: conventional and nonconventional processes

CRC Press

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2019 by Taylor & Francis Group, LLC

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Library of Congress Cataloging-in-Publication Data

Names: El-Hofy, Hassan, author.

Title: Fundamentals of machining processes: conventional and nonconventional

processes/by Hassan El-Hofy.

Description: Third edition. | Boca Raton, FL: CRC Press/Taylor & Francis Group,

[2019] | Includes bibliographical references and index.

Identifiers: LCCN 2018028484| ISBN 9781138334908 (hardback: acid-free paper) |

ISBN 9780429443329 (ebook)

Subjects: LCSH: Machining.

Classification: LCC TJ1185 .E448 2019 | DDC 671.3/5dc23

LC record available at https://lccn.loc.gov/2018028484

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I dedicate this edition of the book
to
The Soul of my late wife Soaad El-Hofy
and
My grandchildren
Omer, Youssef, Zaina, Hassan, Hana, and Ali

Machining processes produce finished parts, ready for use or assembly, at a high degree of accuracy and surface quality by removing a certain machining allowance from the workpiece material. The removal of material can be achieved by cutting abrasion and erosion. Nonconventional machining by erosion of the workpiece material regardless of their mechanical properties has emerged to overcome the drawbacks of conventional machining processes. Hybrid machining processes combine more than one process together to achieve higher machining rates, greater product accuracy, and the best possible surface characteristics. New hard-to-cut materials made it essential to adopt new machining methods such as vibration-assisted machining. The fundamentals of machining composite materials with high strength-to-weight ratio have to be addressed. Techniques of mass finishing operations need to be covered.

Many aspects of the machining subject have been covered in detail and in a scattered way through various machining/manufacturing books, and the author believes that this new edition covers a complete set of machining topics at this level in a single book.

I am glad to present this new revised edition as an outcome to various suggestions and comments received from readers, researches, and professors of various universities. This new edition covers the fundamentals of machining by cutting, abrasion, erosion, and combined processes; high-speed machining, micromachining, machinability concepts; and machining process selection guidelines. Four extra chapters have been added dealing with magnetic-assisted finishing, mass finishing, machining of composites, and vibration-assisted machining.

This new edition is a fundamental textbook for undergraduate students enrolled in production, materials, industrial, mechatronics, marine, and mechanical engineering programs. Additionally, students from other disciplines may find this book helpful with courses in the area of manufacturing engineering. It is also useful for students enrolled in graduate programs related to higher level machining topics. Professional engineers and technicians working in the field of machining technology will find it of value as well. The treatment of the different subjects has been developed from basic principles and does not require knowledge of advanced mathematics as a prerequisite. Along with fundamental theoretical analysis, this book contains machining data, solved examples, and review questions which are useful for students and manufacturing engineers. A solutions manual and power-point presentations are supplied with the book to help those adopting it.

The book is divided into 20 chapters as listed below. A brief description of each follows the list.

Machining Processes

Cutting Tools

Mechanics of Orthogonal Cutting

Tool Wear, Tool Life, and Economics of Metal Cutting

Cutting Cylindrical Surfaces

Cutting Flat Surfaces

High-Speed Machining

Machining by Abrasion

Abrasive Finishing Processes

Modern Abrasive Processes

Magnetic FieldAssisted Finishing Processes

Mass Finishing Processes

Machining by Electrochemical Erosion

Machining by Thermal Erosion

Hybrid Machining Processes

Micromachining

Machining Composite Materials

Vibration-Assisted Machining

Machinability

Machining Process Selection

introduces the history and progress of machining. The importance of machining in manufacturing technology and variables of machining processes are presented. The basics of machining by cutting, abrasion, and erosion are explained and examples are given.

describes the geometry of single-point and multipoint cutting tools, tool materials, properties, selection, and machining conditions.

covers the mechanics of orthogonal cutting including chip formation and the different theories describing the cutting forces, stresses, and material removal process. It discusses heat generation in metal cutting, cutting tool temperature, and cutting fluids.

describes the mechanics of the machining processes used for cutting cylindrical surfaces including turning, drilling, and reaming. For each process, the cutting force, power consumption, machining time, volumetric removal rate, and surface roughness are evaluated.

discusses tool wear, tool life, and the economics of machining processes. The specific cutting speed for minimum cost, maximum production rate/minimum time, and maximum profit rate are quantitatively determined.

covers processes used to cut flat surfaces, such as shaping, milling, and broaching where cutting forces, power consumption, cutting time, surface roughness, and material removal rates are calculated.