Manufacturing Engineering and Technolog

I Edition information
Manufacturing engineering and technology machining Preface()
1 This is the 4th edition of the text book. 2 Characteristics in the previous edition:
In the emphasis on balanced coverage of relevant fundamental and real-ward practice.
3 what is new in the 4th edition:

New Examples and case studies; New questions and problems; Summaries were Completely rewritten and Expanded; Bibliographies updated more Cross-references New or expanded topics are shown in table at the top of page XVIII
Department of Mechanical and electrical Shazhou institute of technology, Zhangjiagang , Rep. Of China Sep. 2006
Kalpakjian Schmid Manufacturing Engineering and Technology
Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006
Page 7-1
Page 7-2
Page 7-3
II Study aids
1 Use extensive schematic diagram() and flowchart to present every topic of the manufacturing engineering technology(MET); 2 Emphasis on uses of the concepts and information presented; 3 Analogies, discussions and problems designed to stimulate() the students curiosity() about consumer and industrial products and how they are manufactured; 4 Extensive reference material include tables,Illustrations,Graphs, and Bibliographies; 5 Numerous Examples and case studies to highlight() important concepts and techniques; 6 Tables comparing advantages and limitations of manufacturing processes 7 A summary, list of key terms, and concise description of current trends at the end of each chapter.
Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-4
III Suitable audience

Audience or readers suitable for this text and course include the students in the majors of :
IV About the authors

Prof. Serope Kalpakjian:
Teach in the Illinois institute of technology Graduated from Robert college, Harvard university and the Massachusetts institute of technology He was a research supervisor in charge of advanced metal-forming processes.
Mechanical Manufacturing Industrial Aerospace Metallurgical() and materials engineering
published numerous papers one of the authors of several encyclopedias editor of several journals wrote three manufacturing books(two of which obtained the M. engene merchant award) life fellow() of ASME fellow and life member of ASM international fellow of the SME full member of the CIRP manufacturing research institution He received: The best paper . Excellence in teaching award Education award one of the founding members and past president of the north American
Page 7-5
Page 7-6
IV About the authors

1
Part IV: Material-removal processes and machines

1 1 previous manufacturing processes: Casting produces a part by means of feeding the fluid metal into a casting cavity and freezing into the shape as the cavity. Forming produces a part by means of squeezing the hot metal to be a specific shape. Shaping () produces a part by means of various methods to force the cold metal to be a specific shape. (a )
Part IV: Why need the material-removal processes

Reason: In many engineering applications, parts must be interchangeable to function properly and reliable during their expected service lives. However, none of the processes described above can produce a part with such accuracy. material-removal processes are desirable for:
Dr. Steven R. Schmid is:

an associate professor in university of Notro Dame Director of the manufacturing tribology() Lab. At university of Notro Dame. He received bachelor degree in the Illinois institute of technology(with honors) Master and Ph. D. degree in Northwestern university numerous awards: the John T. yoursons award the nevkirk award for ASME a national science foundation(NSF) careers award ALCOA foundation award. He published over thirty papers edited three conference proceeding And he has held officer positions in the society of manufacturing engineers and the society of tribology and lubrication engineers. is a registered professional engineer and a certified manufacturing
( b )
dimensional accuracy geometric features finishing operation surface characteristics economical waste materials unless carried out properly, material-removal processes can have adverse effects on the surface quality and properties of the product
Figure 1 Schematic illustration of a sand mold, showing various features
engineer.
Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-7 Kalpakjian Schmid Manufacturing Engineering and Technology
Figure 2 (a) Solid cylindrical billet upset between two flat dies. (b) Uniform deformation of the billet without friction. (c) Deformation with friction.
Figure 3. Bending process
Page 7-8
Page 7-9
Examples of Parts Produced Using the Machining Processes in the Chapter
Examples of Milling Cutters and Operations

Figure 23.2 Some of the basic types of milling cutters and milling operations.
CHAPTER 23
Machining Processes Used to Produce Various Shapes
Figure 23.1 Typical parts and shapes produced with the machining processes described in this chapter.
Page 7-10
Page 7-11
Page 7-12
Example of Part Produced on a CNC Milling Machine

Figure 23.3 A typical part that can be produced on a milling machine equipped with computer controls. Such parts can be made efficiently and repetitively on computer numerical control (CNC) machines, without the need for refixturing or reclamping the part.
Conventional and Climb Milling

Figure 23.4 (a) Schematic illustration of conventional milling and climb milling. (b) Slab milling operation, showing depth of cut, d, feed per tooth, f, chip depth of cut, tc, and workpiece speed, v. (c) Schematic illustration of cutter travel distance lc to reach full depth of cut.
Summary of Milling Parameters and Formulas

TABLE 23.1 N = f = D = n = v = V = Rotational speed of the milling cutter, rpm Feed, mm/tooth or in./tooth Cutter diameter, mm or in. Number of teeth on cutter Linear speed of the workpiece or feed rate, mm/min or in./min Surface speed of cutter, m/min or ft/min =D N f = Feed per tooth, mm/tooth or in/tooth =v /N n l = Length of cut, mm or in. t = Cutting time, s or min =( l+lc ) v , where lc =extent of the cutters first contact with workpiece 3 3 MRR = mm /min or in. /min =w d v , where w is the width of cut Torque = N-m or lb-ft ( Fc ) (D/2) Power = kW or hp = (Torque) ( ), where = 2 N radians/min Note: The units given are those that are commonly used; however, appropriate units must be used in the formulas.
Page 7-13
Page 7-14
Face Milling
Figure 23.5 Face-milling operation showing (a) action of an insert in face milling; (b) climb milling; (c) conventional milling; (d) dimensions in face milling. The width of cut, w, is not necessarily the same as the cutter radius. Source: Ingersoll Cutting Tool Company.
Effects of Insert Shapes Face-Milling Cutter
Figure 23.8 Terminology for a face-milling cutter. Figure 23.6 A face-milling cutter with indexable inserts. Source: Courtesy of Ingersoll Cutting Tool Company.
Figure 23.7 Schematic illustration of the effect of insert shape on feed marks on a face-milled surface: (a) small corner radius, (b) corner flat on insert, and (c) wiper, consisting of a small radius followed by a large radius which leaves smoother feed marks. Source: Kennametal Inc. (d) Feed marks due to various insert shapes.
Page 7-17
Page 7-18
Effect of Lead Angle

Figure 23.9 The effect of lead angle on the undeformed chip thickness in face milling. Note that as the lead angle increase, the chip thickness decreases, but the length of contact (i.e., chip width) increases. The insert in (a) must be sufficiently large to accommodate the contact length increase.
Cutter and Insert Position in Face Milling

Figure 23.10 (a) Relative position of the cutter and insert as it first engages the workpiece in face milling, (b) insert positions towards the end of the cut, and (c) examples of exit angles of insert, showing desirable (positive or negative angle) and undesirable (zero angle) positions. In all figures, the cutter spindle is perpendicular to the page.
Cutters for Different Types of Milling

Figure 23.11 Cutters for (a) straddle milling, (b) form milling, (c) slotting, and (d) slitting with a milling cutter.
Page 7-19
Page 7-20
Page 7-21
Other Milling Operations and Cutters

Figure 23.12 (a) T-slot cutting with a milling cutter. (b) A shell mill.
Arbors
Capacities and Maximum Workpiece Dimensions for Machine Tools

TABLE 23.2 Typical Capacities and Maximum Workpiece Dimensions for Some Machine Tools
Machine tool Milling machines (table travel) Knee-and-column Bed Numerical control Planers (table travel) Broaching machines (length) Gear cutting (gear diameter) Maximum dimension m (ft) 1.4 (4.6) 4.3 (14) 5 (16.5) 10 (33) 2 (6.5) 5 (16.5) Power (kW) 20 Maximum speed 4000 rpm
100 0.9 MN
1.7
Figure 23.13 Mounting a milling cutter on an arbor for use on a horizontal milling machine.
Note: Larger capacities are available for special applications.
Page 7-22
Page 7-23
Page 7-24
TABLE 23.3 Approximate Cost of Selected Tools for Machining*

Size (in.) Cost ($) 1/4 1.002.00 1/2 3.006.00 Coated (TiN) 1/4 2.603.00 1/2 1015 Tapered shank 1/4 2.507.00 1 1545 2 8085 3 250 4 950 Reamers, HSS, hand 1/4 1015 1/2 1015 Chucking 1/2 510 1 2025 1 1/2 4055 End mills, HSS 1/2 1015 1 1530 Carbide-tipped 1/2 3035 1 4560 Solid carbide 1/2 3070 1 180 Burs, carbide 1/2 1020 1 5060 Milling cutters, HSS, staggered tooth, wide 4 3575 8 130260 Collets (5 core) 1 1020 *Cost depends on the particular type of material and shape of tool, its quality, and the amount purchased.
Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-25
TABLE 23.4
General-purpose starting conditions Feed Speed mm/tooth m/min (in./tooth) (ft/min)
0.130.20 (0.0050.008) 120180 (400600)
Tools Drills, HSS, straight shank
Workpiece material
Low-C and freemachining steels Alloy steels Soft
Cutting tool
Uncoated carbide, coated carbide, cermets Uncoated, coated, cermets Cermets, PCBN
Range of conditions Feed Speed mm/tooth m/min (in./tooth) (ft/min)

0.0850.38 (0.0030.015) 90425 (3001400)
General Troubleshooting Guide for Milling Operations

TABLE 23.5
Problem Tool breakage Tool wear excessive Probable causes Tool material lacks toughness; improper tool angles; cutting parameters too high. Cutting parameters too high; improper tool material; improper tool angles; improper cutting fluid. Feed too high; spindle speed too low; too few teeth on cutter; tool chipped or worn; built-up edge; vibration and chatter. Lack of spindle stiffness; excessive temperature rise; dull tool; chips clogging cutter. Dull tool; depth of cut too low; radial relief angle too small. Dull cutting tools; cutter spindle tilt; negative tool angles. Insufficient stiffness of system; external vibrations; feed, depth, and width of cut too large. Dull cutting edges or too much honing; incorrect angle of entry or exit; feed and depth of cut too high; incorrect insert geometry. Lead angle too low; incorrect cutting edge geometry; incorrect angle of entry or exit; feed and depth of cut too high.
Approximate Cost of Selected Tools for Machining
General Recommendations for Milling Operations
Hard Cast iron, gray Soft Hard Stainless steel, austenitic High-temperature alloys, nickel base Titanium alloys Aluminum alloys Free machining High silicon Copper alloys Thermoplastics and thermosets
0.100.18 (0.0040.007) 0.100.15 (0.0040.006) 0.1010.20 (0.0040.008) 0.100.20 (0.0040.008) 0.130.18 (0.0050.007) 0.100.18 (0.0040.007) 0.130.15 (0.0050.006) 0.130.23 (0.0050.009) 0.13 (0.005) 0.130.23 (0.0050.009) 0.130.23 (0.0050.009)
90170 (300550) 180210 (600700) 120760 (4002500) 120210 (400700) 120370 (4001200) 30370 (1001200) 5060 (175200) 610900 (20003000) 610 (2000) 300760 (10002500) 270460 (9001500)
0.080.30 (0.0030.012) 0.080.25 (0.0030.010) 0.080.38 (0.0030.015) 0.080.38 (0.0030.015) 0.080.38 (0.0030.015) 0.080.38 (0.0030.015) 0.080.38 (0.0030.015) 0.080.46 (0.0030.018) 0.080.38 (0.0030015) 0.080.46 (0.0030.018) 0.080.46 (0.0030.018)
60370 (2001200) 75460 (2501500) 901370 (3004500) 90460 (3001500) 90500 (3001800) 30550 (901800) 40140 (125450) 3003000 (100010,000) 370910 (12003000) 901070 (3003500) 901370 (3004500)
Uncoated, coated, cermets, SiN Cermets, SiN, PCBN Uncoated, coated, cermets Uncoated, coated, cermets, SiN, PCBN Uncoated, coated, cermets Uncoated, coated, PCD PCD Uncoated, coated, PCD Uncoated, coated, PCD
Rough surface finish Tolerances too broad Workpiece surface burnished Back striking Chatter marks Burr formation Breakout
Source: Based on data from Kennametal Inc. Note: Depths of cut, d , usually are in the range of 18 mm (0.040.3 in.). PCBN: polycrystalline cubic boron nitride; PCD: polycrystalline diamond. Note: See also Table 22.2 for range of cutting speeds within tool material groups.
Page 7-26
Page 7-27
Surface Features and Corner Defects
Horizontal- and Vertical-Spindle Column-andKnee Type Milling Machines

Figure 23.15 Schematic illustration of a horizontalspindle column-and-knee type milling machine. Source: G. Boothroyd.
Bed-Type Milling Machine

Figure 23.17 Schematic illustration of a bed-type milling machine. Note the single vertical-spindle cutter and two horizontal spindle cutters. Source: ASM International.
Figure 23.14 Surface features and corner defects in face milling operations; see also Fig. 23.7. For troubleshooting, see Table 23.5. Source: Kennametal Inc.
Figure 23.16 Schematic illustration of a vertical-spindle column-and-knee type milling machine (also called a knee miller). Source: G. Boothroyd.
Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-29 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-30
Page 7-28
Additional Milling Machines

Figure 23.18 A computer numerical control, vertical-spindle milling machine. This machine is one of the most versatile machine tools. Source: Courtesy of Bridgeport Machines Division, Textron Inc.
Examples of Parts Made on a Planer and by Broaching

Figure 23.20 Typical parts that can be made on a planer.
Broaches
Figure 23.19 Schematic illustration of a five-axis profile milling machine. Note that there are three principal linear and two angular movements of machine components
Figure 23.22 (a) Cutting action of a broach, showing various features. (b) Terminology for a broach.
Figure 23.21 (a) Typical parts made by internal broaching. (b) Parts made by surface broaching. Heavy lines indicate broached surfaces. Source: General Broach and Engineering Company.
Page 7-31 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-32 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-33
Chipbreakers and a Broaching Machine

Figure 23.23 Chipbreaker features on (a) a flat broach and (b) a round broach. (c) Vertical broaching machine. Source: Ty Miles, Inc. (a) (c)
Internal Broach and Turn Broaching
Broaching Internal Splines
(b) Figure 23.24 Terminology for a pull-type internal broach used for enlarging long holes. Figure 23.25 Turn broaching of a crankshaft. The crankshaft rotates while the broaches pass tangentially across the crankshafts bearing surfaces. Source: Courtesy of Ingersoll Cutting Tool Company. Figure 23.26
Page 7-34
Page 7-35
Page 7-36
Sawing Operations
Figure 23.27 Examples of various sawing operations. Source: DoALL Company.
Types of Saw Teeth
Saw Teeth and Burs

Figure 23.29 (a) High-speed-steel teeth welded on steel blade. (b) Carbide inserts brazed to blade teeth.
Figure 23.30 Types of burs. Source: The Copper Group.
Figure 23.28 (a) Terminology for saw teeth. (b) Types of tooth set on saw teeth, staggered to provide clearance for the saw blade to prevent binding during sawing.
Page 7-37
Page 7-38
Page 7-39
Spur Gear
Figure 23.31 Nomenclature for an involute spur gear. Figure 23.32 (a) Producing gear teeth on a blank by from cutting. (b) Schematic illustration of gear generating with a pinionshaped gear cutter. (c) Schematic illustration of gear generating in a gear shaper using a pinionshaped cutter. Note that the cutter reciprocates vertically. (d) Gear generating with rackshaped cutter.
Gear Generating
Gear Cutting With a Hob

Figure 23.33 Schematic illustration of three views of gear cutting with a hob. Source: After E. P. DeGarmo and Society of Manufacturing Engineers
Page 7-40
Page 7-41
Page 7-42
Cutting Bevel Gears
Gear Grinding
Figure 23.25 Finishing gears by grinding: (a) form grinding with shaped grinding wheels; (b) grinding by generating with two wheels.
Economics of Gear Production

Figure 23.36 Gear manufacturing cost as a function of gear quality. The numbers along the vertical lines indicate tolerances. Source: Society of Manufacturing Engineers.
Figure 23.34 (a) Cutting a straight bevel-gear blank with two cutters. (b) Cutting a spiral bevel gear with a single cutter. Source: ASM International.
Page 7-43
Page 7-44
Page 7-45
Examples of Parts Machined on Machining Centers

Figure 24.1 Examples of parts that can be machined on machining centers, using various processes such as turning, facing, milling, drilling, boring, reaming, and threading. Such parts would ordinarily require a variety of machine tools. Source: Toyoda Machinery.
Horizontal-Spindle Machining Center

Figure 24.2 A horizontal-spindle machining center, equipped with an automatic tool changes. Tool magazines can store 200 cutting tools. Source: Courtesy of Cincinnati Milacron, Inc.
CHAPTER 24
Machining and Turning Centers, Machine-Tool Structures, and Machining Economics
Page 7-46
Page 7-47
Page 7-48
Five-Axis Machining Center

Figure 24.3 Schematic illustration of a five-axis machining center. Note that in addition to the three linear movements, the pallet can be swiveled (rotated) along two axes, allowing the machining of complex shapes such as those shown in Fig. 24.1. Source: Toyoda Machinery.
Pallets
Swing-Around Tool Changer

Figure 24.5 Swing-around tool changer on a horizontal-spindle machining center. Source: Cincinnati Milacron, Inc.
Figure 24.4 (a) Schematic illustration of the top view of a horizontal-spindle machining center showing the pallet pool, set-up station for a pallet, pallet carrier, and an active pallet in operation (shown directly below the spindle of the machine). (b) Schematic illustration of two machining centers with a common pallet pool. Various other arrangements are possible in such systems. Source: Hitachi Seiki Co., Ltd.
Page 7-49
Page 7-50
Page 7-51
Touch Probes
Figure 24.6 Touch probes used in machining centers for determining workpiece and tool positions and surfaces relative to the machine table or column. (a) Touch probe determining the X-Y (horizontal) position of a workpiece, (b) determining the height of a horizontal surface, (c) determining the planar position of the surface of a cutter (for instance, for cutter-diameter compensation), and (d) determining the length of a tool for tool-length offset. Source: Hitachi Seiki Co., Ltd.
Vertical-Spindle Machining Center

Figure 24.7 A vertical-spindle machining center. The tool magazine is on the left of the machine. The control panel on the right can be swiveled by the operator. Source: Courtesy of Cincinnati Milacron, Inc.
CNC Turning Center
Figure 24.8 Schematic illustration of a three-turret, two-spindle computer numerical controlled turning center. Source: Hitachi Seiki Co., Ltd.
Page 7-52
Page 7-53
Page 7-54
Chip-Collecting System
Machining Outer Bearing Races on a Turning Center

Figure 24.10
Machine-Tool Structure and Guideways

Figure 24.11 An example of a machinetool structure. The boxtype, one-piece design with internal diagonal ribs significantly improves the stiffness of the machine. Source: Okuma Machinery Works Ltd.
Figure 24.12 Steel guideways integrally-cast on top of the cast-iron bed of a machining center. Because of its higher elastic modulus, the steel provides higher stiffness than cast iron. Source: Hitachi Seiki Co., Ltd.
Figure 24.9 Schematic illustration of a chip-collecting system in a horizontalspindle machining center. The chips that fall by gravity are collected by the two horizontal conveyors at the bottom of the troughs. Source: Okuma Machinery Works Ltd.
Page 7-55
Page 7-56
Page 7-57
Chatter
Internal Damping of Structural Materials
Joints in Machine-Tool Structures

Figure 24.15 The damping of vibrations as a function of the number of components on a lathe. Joints dissipate energy; the greater the number of joints, the higher the damping capacity of the machine. Source: J. Peters.
Figure 24.13 Chatter marks (right of center of photograph) on the surface of a turned part. Source: General Electric Company.
Figure 24.14 The relative damping capacity of (a) gray cast iron and (b) epoxygranite composite material. The vertical scale is the amplitude of vibration and the horizontal scale is time. Source: Cincinnati Milacron, Inc.
Page 7-58
Page 7-59
Page 7-60
Examples of Bonded Abrasives
Machining Economics
CHAPTER 25
Figure 24.16 Graphs showing (a) cost per piece and (b) time per piece in machining. Note the optimum speeds for both cost and time. The range between the two is known as the highefficiency machining range.
Abrasive Machining and Finishing Operations

Figure 25.1 A variety of bonded abrasives used in abrasive machining processes. Source: Courtesy of Norton Company.
Page 7-61
Page 7-62
Page 7-63
General Characteristics of Abrasive Machining Processes and Machines

TABLE 25.1 Process Surface Characteristics Flat surfaces on most materials; production rate depends on table size and automation; labor skill depends on part; production rate is high on vertical-spindle rotary-table type. Round workpieces with stepped diameters; low production rate unless automated; labor skill depends on part shape. Maximum dimension (m)* Reciprocating table L : 6 Rotary table D : 3 Workpiece D : 0.8 Roll grinders D : 1.8 Universal grinders D : 2.5 Workpiece D : 0.8 Hole D : 2 Spindle D : 1.2 Table D : 3.7
Workpiece Geometries
Knoop Hardness for Various Materials and Abrasives

TABLE 25.2
Cylindrical
Centerless Round workpieces; high production rate; low to medium labor skill. Internal Bores in workpiece; low production rate; low to medium labor skill. Honing Bores and holes in workpiece; low production rate; low labor skill. Lapping Flat surfaces; high production rate; low labor skill. Ultrasonic Holes and cavities of various shapes, particularly in hard and brittle machining nonconducting materials. *Larger capacities are available for special applications. L=length; D=diameter.
Common glass Flint, quartz Zirconium oxide Hardened steels Tungsten carbide Aluminum oxide
350500 8001100 1000 7001300 18002400 20003000
Titanium nitride Titanium carbide Silicon carbide Boron carbide Cubic boron nitride Diamond
2000 18003200 21003000 2800 40005000 70008000
Figure 25.2 The types of workpieces and operations typical of grinding: (a) cylindrical surfaces, (b) conical surfaces, (c) fillets on a shaft, (d) helical profiles, (e) concave shape, (f) cutting off or slotting with thin wheels, and (g) internal grinding. See also the illustrations in Section 25.6.
Page 7-64
Page 7-65
Page 7-66
Grinding Wheel
Figure 25.3 Schematic illustration of a physical model of a grinding wheel, showing its structure and wear and fracture patterns.
Common Grinding Wheels

Figure 25.4 Common types of grinding wheels made with conventional abrasives. Note that each wheel has a specific grinding face; grinding on other surfaces is improper and unsafe.
Superabrasive Wheel Configurations

Figure 25.5 Examples of superabrasive wheel configurations. The annular regions (rim) are superabrasive grinding surfaces, and the wheel itself (core) is generally made of metal or composites. The bonding materials for the superabrasives are (a), (d), and (e) resinoid, metal, or vitrified, (b) metal, (c) vitrified, and (f) resinoid.
Page 7-67
Page 7-68
Page 7-69
Marking System for Aluminum-Oxide and Silicon-Carbide Bonded Abrasives

Figure 25.6 Standard marking system for aluminum-oxide and silicon-carbide bonded abrasives.
Standard Marking System for Cubic Boron Nitride and Diamond Bonded Abrasives
Figure 25.7 Standard marking system for cubic boron nitride and diamond bonded abrasives. (a)
Grinding Chips
(b)
Figure 25.8 (a) Grinding chip being produced by a single abrasive grain. (A) chip, (B) workpiece, (C) abrasive grain. Note the large negative rake angle of the grain. The inscribed circle is 0.065 mm (0.0025 in.) in diameter. Source: M. E. Merchant. (b) Schematic illustration of chip formation by an abrasive grain with a wear flat. Note the negative rake angle of the grain and the small shear angle.
Page 7-70
Page 7-71
Page 7-72
Surface Grinding and Plowing Grinding Wheel Surface

Figure 25.9 The surface of a grinding wheel (A46-J8V) showing abrasive grains, wheel porosity, wear flats on grains, and metal chips from the workpiece adhering to the grians. Note the random distribution and shape of abrasive grains. Magnification: 50X. Source: S. Kalpakjian. Figure 25.10 Schematic illustration of the surface grinding process, showing various process variables. The figure depicts conventional (up) grinding.
Approximate Specific Energy Requirements for Surface Grinding

TABLE 25.3 Specific energy Workpiece material Aluminum Cast iron (class 40) Low-carbon steel (1020) Titanium alloy Tool steel (T15) Hardness 150 HB 215 HB 110 HB 300 HB 67 HRC W-s/mm 727 1260 1468 1655 1882
3 3
hp-min/in. 2.510 4.522 525 620 6.530
Figure 25.11 Chip formation and plowing of the workpiece surface by an abrasive grain. This action is similar to abrasive wear. (See Fig. 32.6).
Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-73 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-74 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-75
Shaping Using Computer Control

Figure 25.12 Shaping the grinding face of a wheel by dressing it with computer control. Note that the diamond dressing tool is normal to the surface at point of contact with the wheel. Source: Okuma Machinery Works Ltd.
Speed and Feed Ranges and Grinding Wheel Recommendations

TABLE 25.4 Typical Range of Speeds and Feeds for Abrasive Processes Conventional Creep-feed Process variable grinding grinding Buffing Wheel speed (m/min) 15003000 15003000 18003600 Work speed (m/min) 1060 0.11 Feed (mm/pass) 0.010.05 16
TABLE 25.5 Typical Recommendations for Grinding W heels for Use with Various M aterials M aterial Type of grinding wheel C46K6V Aluminum C46K6V Brass A54K6V Bronze C60L6V, A60M 6V Cast iron C60I9V, D150R75B Carbides D150N50M Ceramics C60J8V Copper B150H100V Nickel alloys A36L8V Nylon A60M 6V Steels A60K8V Titanium B120W B Tool steels ( > 50 HRC) Note: These recommendations vary significantly, depending on material composition, the particular grinding operation, and grinding fluids used.
Page 7-76 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-77
Surface Grinding Operations

Figure 25.13 Schematic illustrations of various surface grinding operations. (a) Traverse grinding with a horizontal-spindle surface grinder. (b) Plunge grinding with a horizontal-spindle surface grinder, producing a groove in the workpiece. (c) A vertical-spindle rotary-table grinder (also known as the Blanchard type).
Polishing 15002400
Page 7-78
Surface Grinding
Figure 25.14 Schematic illustration of a horizontal-spindle surface grinder.
Cylindrical Grinding Operations
Plunge and Noncylindrical Grinding

Figure 25.17 Plunge grinding of a workpiece on a cylindrical grinder with the wheel dressed to a stepped shape. See also Fig. 25.12.
Figure 25.15 (a) Rough grinding of steel balls on a vertical-spindle grinder; the balls are guided by a special rotary fixture. (b) Finish grinding of balls in a multiple-groove fixture. The balls are ground to within 0.013 mm (0.0005 in.) of their final size. Source: American Machinist.
Figure 25.16 Examples of various cylindrical grinding operations. (a) Traverse grinding, (b) plunge grinding, and (c) profile grinding. Source: Okuma Machinery Works Ltd.
Figure 25.18 Schematic illustration of grinding a noncylindrical part on a cylindrical grinder with computer controls to produce the shape. The part rotation and the distance x between centers is varied and synchronized to grind the particular workpiece shape.
Page 7-80
Thread and Internal Grinding
Cycle Patterns in Cylindrical Grinding

Figure 25.20
Centerless Grinding
Figure 25.19 Thread grinding by (a) traverse, and (b) plunge grinding.
(c)
Figure 25.22 Schematic illustrations of centerless grinding operations: (a) through feed grinding. (b) Plunge grinding. (c) A computer numerical control cylindrical grinding machine. Source: Courtesy of Cincinnati Milacron, Inc.
Figure 25.21 Schematic illustrations of internal grinding operations.
Page 7-82
Page 7-83
Page 7-84
Creep-Feed Grinding General Recommendations for Grinding Fluids

(a) (b) (c)
Ultrasonic Machining and Coated Abrasives

Figure 25.24 (a) Schematic illustration of the ultrasonic machining process. (b) and (c) Types of parts made by this process. Note the small size of holes produced.
Figure 25.23 (a) Schematic illustration of the creep-feed grinding process. Note the large wheel depth of cut, d. (b) A shaped groove produced on a flat surface by creep-feed grinding in one pass. Groove depth is typically on the order of a few mm. (c) An example of creep-feed grinding with a shaped wheel. This operation can also be performed by some of the processes described in Chapter 26. Source: Courtesy of Blohm, Inc., and Manufacturing Engineering Magazine, Society of Manufacturing Engineers.
TABLE 25.6 Material Grinding fluid E, EP Aluminum CSN, E, MO FO Copper D, MO Magnesium CSN, EP Nickel EP Refractory metals CSN, E Steels CSN, E Titanium D: dry; E: emulsion; EP: Extreme pressure; CSN: chemicals and synthetics; MO: mineral oil; FO: fatty oil.
Figure 25.25 Schematic illustration of the structure of a coated abrasive. Sandpaper, developed in the 16th century, and emery cloth are common examples of coated abrasives.
Page 7-85
Page 7-86
Page 7-87
Belt Grinding
Figure 25.26 Example: Belt Grinding of Turbine Nozzle Vanes.
Honing and Superfinishing

Figure 25.27 Schematic illustration of a honing tool used to improve the surface finish of bored or ground holes.
Lapping
Figure 25.29 (a) Schematic illustration of the lapping process. (b) Production lapping on flat surfaces. (c) Production lapping on cylindrical surfaces.
Figure 25.28 Schematic illustrations of the superfinishing process for a cylindrical part. (a) Cylindrical mircohoning, (b) Centerless microhoning.
Page 7-88
Page 7-89
Page 7-90
10
Polishing Using Magnetic Fields
Abrasive-Flow Machining
Figure 25.31 Schematic illustration of abrasive flow machining to deburr a turbine impeller. The arrows indicate movement of the abrasive media. Note the special fixture, which is usually different for each part design. Source: Extrude Hone Corp.
Robotic Deburring
Figure 25.32 A deburring operation on a robot-held die-cast part for an outboard motor housing, using a grinding wheel. Abrasive belts (Fig. 25.26) or flexible abrasive radialwheel brushes can also be used for such operations. Source: Courtesy of Acme Manufacturing Company and Manufacturing Engineering Magazine, Society of Manufacturing Engineers.
Figure 25.30 Schematic illustration of polishing of balls and rollers using magnetic fields. (a) Magnetic float polishing of ceramic balls. (b) Magnetic-field-assisted polishing of rollers. Source: R. Komanduri, M. Doc, and M. Fox.
Page 7-91
Page 7-92
Page 7-93
Economics of Grinding and Finishing Operations
Examples of Parts Made by Advanced Machining Processes
CHAPTER 26
Advanced Machining Processes and Nanofabrication
Figure 25.33 Increase in the cost of machining and finishing a part as a function of the surface finish required. This is the main reason that the surface finish specified on parts should not be any finer than necessary for the part to function properly.
(a)
(b)
Figure 26.1 Examples of parts made by advanced machining processes. These parts are made by advanced machining processes and would be difficult or uneconomical to manufacture by conventional processes. (a) Cutting sheet metal with a laser beam. Courtesy of Rofin-Sinar, Inc., and Manufacturing Engineering Magazine, Society of Manufacturing Engineers. (b) Microscopic gear with a diameter on the order of 100 m, made by a special etching process. Courtesy of Wisconsin Center for Applied Microelectronics, University of Wisconsin-Madison.
Page 7-94
TABLE 26. 1 Process parameters and typical material removal rate or cutting speed 0.00250.1 mm/min.
Chemical Milling Chemical Machining

2
Process Chemical machining (CM)
Electrochemical machining (ECM)
General Characteristics of Advanced Machining Processes
Electrochemical grinding (ECG) Electrical-discharge machining (EDM)
Wire EDM Laser-beam machining (LBM) Electron-beam machining (EBM) Water-jet machining (WJM)
Abrasive water-jet machining (AWJM) Abrasive-jet machining (AJM)
Characteristics Shallow removal (up to 12 mm) on large flat or curved surfaces; blanking of thin sheets; low tooling and cost; suitable for low production runs. Complex shapes with deep cavities; highest rate of material removal among nontraditional processes; expensive tooling and equipment; high power consumption; medium to high production quantity. Cutting off and sharpening hard materials, such as tungsten-carbide tools; also used as a honing process; higher removal rate than grinding. Shaping and cutting complex parts made of hard materials; some surface damage may result; also used as a grinding and cutting process; expensive tooling and equipment. Contour cutting of flat or curved surfaces; expensive equipment. Cutting and holemaking on thin materials; heataffected zone; does not require a vacuum; expensive equipment; consumes much energy. Cutting and holemaking on thin materials; very small holes and slots; heat-affected zone; requires a vacuum; expensive equipment. Cutting all types of nonmetallic materials to 25 mm and greater in thickness; suitable for contour cutting of flexible materials; no thermal damage; noisy. Single or multilayer cutting of metallic and nonmetallic materials. Cutting, slotting, deburring, deflashing, etching, and cleaning of metallic and nonmetallic materials; manually controlled; tends to round off sharp edges; hazardous.
V: 525 dc; A: 1.58 A/mm ; 2.512 mm/min, depending on current density. A: 13 A/mm ; Typically 25 3 mm /s per 1000 A. V: 50380; A: 0.1500; 3 Typically 300 mm /min.
2
Figure 26.3 (a) Schematic illustration of the chemical machining process. Note that no forces or machine tools are involved in this process. (b) Stages in producing a profiled cavity by chemical machining; note the undercut.
Varies with material and thickness. 0.507.5 m/min.
12 mm /min.
Varies considerably with material. Up to 7.5 m/min. Varies considerably with material.
Figure 26.2 (a) Missile skin-panel section contoured by chemical milling to improve the stiffnessto-weight ratio of the part. (b) Weight reduction of space launch vehicles by chemical milling aluminum-alloy plates. These panels are chemically milled after the plates have first been formed into shape by processes such as roll forming or stretch forming. The design of the chemically machined rib patterns can be modified readily at minimal cost. Source: Advanced Materials and Processes, December 1990. ASM International.
Page 7-97
11
Range of Surface Roughnesses and Tolerances
Chemical Blanking and Electrochemical Machining

Figure 26.5 Various parts made by chemical blanking. Note the fine detail. Source: Courtesy of Buckbee-Mears St. Paul.
Examples of Parts Made by Electrochemical Machining

Figure 26.7 Typical parts made by electrochemical machining. (a) Turbine blade made of a nickel alloy, 360 HB; note the shape of the electrode on the right. Source: ASM International. (b) Thin slots on a 4340-steel roller-bearing cage. (c) Integral airfoils on a compressor disk.
Figure 26.4 Surface roughness and tolerances obtained in various machining processes. Note the wide range within each process (see also Fig. 22.13). Source: Machining Data Handbook, 3rd ed. Copyright 1980. Used by permission of Metcut Research Associates, Inc.
Figure 26.6 Schematic illustration of the electrochemicalmachining process. This process is the reverse of electroplating, described in Section 33.8.
Biomedical Implant Electrochemical Grinding

(a) (b) (a)
Electrical-Discharge Machining
(b) (c)
Figure 26.9 (a) Schematic illustration of the electrochemical-grinding process. (b) Thin slot produced on a round nickel-alloy tube by this process. Figure 26.8 (a) Two total knee replacement systems showing metal implants (top pieces) with an ultrahigh molecular weight polyethylene insert (bottom pieces). (b) Cross-section of the ECM process as applied to the metal implant. Source: Biomet, Inc. Figure 26.10 (a) Schematic illustration of the electrical-discharge machining process. This is one of the most widely used machining processes, particularly for die-sinking operations. (b) Examples of cavities produced by the electrical-discharge machining process, using shaped electrodes. Two round parts (rear) are the set of dies for extruding the aluminum piece shown in front (see also Fig. 15.9b). Source: Courtesy of AGIE USA Ltd. (c) A spiral cavity produced by EDM using a slowly rotating electrode, similar to a screw thread. Source: American Machinist.
Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006
Page 7-103
Page 7-104
Page 7-105
Examples of EDM
(a) Figure 26.11 Stepped cavities produced with a square electrode by the EDM process. The workpiece moves in the two principal horizontal directions (x-y), and its motion is synchronized with the downward movement of the electrode to produce these cavities. Also shown is a round electrode capable of producing round or elliptical cavities. Source: Courtesy of AGIE USA Ltd.
Wire EDM
Figure 26.13 (a) Schematic illustration of the wire EDM process. As much as 50 hours of machining can be performed with one reel of wire, which is then discarded. (b) Cutting a thick plate with wire EDM. (c) A computer-controlled wire EDM machine. Source: Courtesy of AGIE USA Ltd. (c)
Laser-Beam Machining
Figure 26.14 (a) Schematic illustration of the laser-beam machining process. (b) and (c) Examples of holes produced in nonmetallic parts by LBM.
(b) Figure 26.12 Schematic illustration of producing an inner cavity by EDM, using a specially designed electrode with a hinged tip, which is slowly opened and rotated to produce the large cavity. Source: Luziesa France.
Page 7-106
Page 7-107
Page 7-108
12
General Applications of Lasers in Manufacturing

TABLE 26.2 Application Laser type Cutting Metals PCO2 , CWCO2 , Nd : YAG, ruby Plastics CWCO2 Ceramics PCO2 Drilling Metals PCO2 , Nd : YAG, Nd : glass, ruby Plastics Excimer Marking Metals PCO2 , Nd : YAG Plastics Excimer Ceramics Excimer Surface treatment, metals CWCO2 Welding, metals PCO2 , CWCO2 , Nd : YAG, Nd : glass, ruby Note: P pulsed, CW continuous wave.
Electron-Beam Machining
(a)
Water-Jet Machining
(b)
(c)
Figure 26.15 Schematic illustration of the electron-beam machining process. Unlike LBM, this process requires a vacuum, so workpiece size is limited to the size of the vacuum chamber.
Figure 26.16 (a) Schematic illustration of water-jet machining. (b) A computer-controlled, water-jet cutting machine cutting a granite plate. (c) Examples of various nonmetallic parts produced by the water-jet cutting process. Source: Courtesy of Possis Corporation.
Page 7-110 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-111
Page 7-109
Abrasive-Jet Machining Nanofabrication

(a) (b)
CHAPTER 27
Fusion-Welding Processes
Figure 26.17 Schematic illustration of the abrasive-jet machining process. Figure 26.18 (a) A scanning electron microscope view of a diamond-tipped (triangular piece at the right) cantilever used with the atomic force microscope. The diamond tip is attached to the end of the cantilever with an adhesive. (b) Scratches produced on a surface by the diamond tip under different forces. Note the extremely small size of the scratches.
Page 7-112
Page 7-113
Page 7-114
General Characteristics of Fusion Welding Processes

TABLE 27.1
Joining process Shielded metal-arc Submerged arc Gas metal-arc Gas tungsten-arc Flux-cored arc Oxyfuel Operation Manual Automatic Semiautomatic or automatic Manual or automatic Semiautomatic or automatic Manual Advantage Portable and flexible High deposition Most metals Most metals High deposition Portable and flexible Most metals Skill level required High Low to medium Low to high Low to high Low to high High Medium to high Welding position All Flat and horizontal All All All All All Current type ac, dc ac, dc dc ac, dc dc Distortion* 1 to 2 1 to 2 2 to 3 2 to 3 1 to 3 2 to 4 3 to 5 Cost of equipment Low Medium Medium to high Medium Medium Low High
Oxyacetylene Flames Used in Welding
Torch Used in Oxyacetylene Welding

Figure 27.2 (a) General view of and (b) cross-section of a torch used in oxyacetylene welding. The acetylene valve is opened first; the gas is lit with a spark lighter or a pilot light; then the oxygen valve is opened and the flame adjusted. (c) Basic equipment used in oxyfuel-gas welding. To ensure correct connections, all threads on acetylene fittings are left-handed, whereas those for oxygen are right-handed. Oxygen regulators are usually painted green, acetylene regulators red.
Electron-beam, Semiautomatic Laser-beam or automatic * 1, highest; 5, lowest.
Figure 27.1 Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing, flame. The gas mixture in (a) is basically equal volumes of oxygen and acetylene.
Page 7-115
Page 7-116
Page 7-117
13
Shielded Metal-Arc Welding Pressure-Gas Welding

Figure 27.3 Schematic illustration of the pressure-gas welding process. Figure 27.4 Schematic illustration of the shielded metal-arc welding process. About 50% of all large-scale industrial welding operations use this process.
Multiple Pass Deep Weld

Figure 27.6 A deep weld showing the buildup sequence of individual weld beads.
Figure 27.5 Schematic illustration of the shielded metal-arc welding operations (also known as stick welding, because the electrode is in the shape of a stick).
Page 7-118
Page 7-119
Page 7-120
Submerged-Arc Welding
Gas Metal-Arc Welding
Equipment Used in Gas Metal-Arc Welding

Figure 27.9 Basic equipment used in gas metal-arc welding operations. Source: American Welding Society.
Figure 27.7 Schematic illustration of the submerged-arc welding process and equipment. The unfused flux is recovered and reused. Source: American Welding Society.
Figure 27.8 Schematic illustration of the gas metal-arc welding process, formerly known as MIG (for metal inert gas) welding.
Page 7-121
Page 7-122
Page 7-123
Flux-Cored Arc-Welding
Figure 27.10 Schematic illustration of the flux-cored arc-welding process. This operation is similar to gas metal-arc welding, showing in Fig. 27.8.
Electrogas Welding
Figure 27.11 Schematic illustration of the electrogas welding process. Source: American Welding Society.
Equipment for Electroslag Welding

Figure 27.12 Equipment used for electroslag welding operations. Source: American Welding Society.
Page 7-124
Page 7-125
Page 7-126
14
Designations for Mild Steel Coated Electrodes

TABLE 27.2 The prefix E designates arc welding electrode. The first two digits of four-digit numbers and the first three digits of five-digit numbers indicate minimum tensile strength: E60XX 60,000 psi minimum tensile strength E70XX 70,000 psi minimum tensile strength E110XX 110,000 psi minimum tensile strength The next-to-last digit indicates position: EXX1X All positions EXX2X Flat position and horizontal fillets The last two digits together indicate the type of covering and the current to be used. The suffix (Example: EXXXX-A1) indicates the approximate alloy in the weld deposit: A1 0.5% Mo B1 0.5% Cr, 0.5% Mo B2 1.25% Cr, 0.5% Mo B3 2.25% Cr, 1% Mo B4 2% Cr, 0.5% Mo B5 0.5% Cr, 1% Mo C1 2.5% Ni C2 3.25% Ni C3 1% Ni, 0.35% Mo, 0.15% Cr D1 and D2 0.250.45% Mo, 1.75% Mn G 0.5% min. Ni, 0.3% min. Cr, 0.2% min. Mo, 0.1%min. V, 1% min. Mn (only one element required)
Gas Tungsten-Arc Welding

Figure 27.13 The gas tungsten-arc welding process, formerly known as TIG (for tungsten inert gas) welding.
Plasma-Arc Welding
Figure 27.15 Two types of plasma-arc welding processes: (a) transferred, (b) nontransferred. Deep and narrow welds can be made by this process at high welding speeds.
Figure 27.14 Equipment for gas tungsten-arc welding operations. Source: American Welding Society.
Page 7-127
Comparison of Laser-Beam and Tungsten-Arc Welding

Figure 27.16 Comparison of the size of weld beads in (a) electron-beam or laser-beam welding to that in (b) conventional (tungsten-arc) welding. Source: American Welding Society, Welding Handbook (8th ed.), 1991.
Example of Laser Welding
Flame Cutting and Drag Lines

Figure 27.18 (a) Flame cutting of steel plate with an oxyacetylene torch, and a crosssection of the torch nozzle. (b) Cross-section of a flame-cut plate showing drag lines.
Figure 27.17 Laser welding of razor blades.
Page 7-130
Page 7-131
Page 7-132
Roll Bonding
(a)
Ultrasonic Welding
(b)
CHAPTER 28
Solid-State Welding Processes
Figure 28.1 Schematic illustration of the roll bonding, or cladding, process
Figure 28.2 (a) Components of an ultrasonic welding machine for lap welds. The lateral vibrations of the tool tip cause plastic deformation and bonding at the interface of the workpieces. (b) Ultrasonic seam welding using a roller. (c) An ultrasonically welded part.
Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-133 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-134 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-135
15
Friction Welding
(a)
Friction Stir Welding

Figure 28.5 (a) Sequence in resistance spot welding. (b) Cross-section of a spot weld, showing the weld nugget and the indentation of the electrode on the sheet surfaces. This is one of the most commonly used process in sheetmetal fabrication and in automotive-body assembly.
Resistance Spot Welding
(b)
Figure 28.4 The principle of the friction stir welding process. Aluminum-alloy plates up to 75 mm (3 in.) thick have been welded by this process. Source: TWI, Cambridge, U.K.
Figure 28.3 (a) Sequence of operations in the friction welding process: (1) Left-hand component is rotated at high speed. (2) Right-hand component is brought into contact under an axial force. (3) Axial force is increased; flash begins to form. (4) Left-hand component stops rotating; weld is completed. The flash can subsequently be removed by machining or grinding. (b) Shape of fusion zone in friction welding, as a function of the force applied and the rotational speed.
Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006
Page 7-136
Page 7-137
Page 7-138
Welding Machine Design
Figure 28.6 (a) Schematic illustration of an air-operated rocker-arm spotwelding machine. Source: American Welding Society. (b) and (c) Electrode designs for easy access into components to be welded.
Examples of Spot Welding

(a) (b)
Spot Welding Example

Figure 28.8 Robots equipped with spot-welding guns and operated by computer controls, in a mass-production line for automotive bodies. Source: Courtesy of Cincinnati Milacron, Inc.
(c)
Figure 28.7 (a) and (b) Spotwelded cookware and muffler. (c) An automated spotwelding machine with a programmable robot; the welding tip can move in three principal directions. Sheets as large as 2.2 m X 0.55 m (88 in. X 22 in.) can be accommodated in this machine. Source: Courtesy of Taylor-Winfield Corporation.
Page 7-139
Page 7-140
Page 7-141
Resistance Seam Welding High-Frequency Butt Welding

Figure 28.9 (a) Seamwelding process in which rotating rolls act as electrodes. (b) Overlapping spots in a seam weld. (c) Roll spot welds. (d) Resistance-welded gasoline tank.
Resistance Projection Welding

Figure 28.11 (a) Schematic illustration of resistance projection welding. (b) A welded bracket. (c) and (d) Projection welding of nuts or threaded bosses and studs. Source: American Welding Society. (e) Resistance-projectionwelded grills.
Figure 28.10 Two methods of high-frequency butt welding of tubes.
Page 7-142
Page 7-143
Page 7-144
16
Flash Welding
Figure 28.12 (a) Flash-welding process for end-to-end welding of solid rods or tubular parts. (b) and (c) Typical parts made by flash welding. (d) Design Guidelines for flash welding.
Stud Welding
Comparison of Conventional and Laser-Beam Welding

Figure 28.14 The relative sizes of the weld beads obtained by conventional (tungsten arc) and by electron-beam or laser-beam welding.
Figure 28.13 The sequence of operations in stud welding, which is used for welding bars, threaded rods, and various fasteners onto metal plates.
Page 7-145
Page 7-146
Page 7-147
Explosion Welding
(a) (b)
Diffusion Bonding Applications

Figure 28.16
Diffusion Bonding/Superplastic Forming
(c)
(d)
Figure 28.15 Schematic illustration of the explosion welding process: (a) constant interface clearance gap and (b) angular interface clearance gap. (c) and (d) Crosssections of explosion-welded joints. (c) titanium (top piece) on low-carbon steel (bottom). (d) Incoloy 800 (an ironnickel-based alloy) on lowcarbon steel. Source: Courtesy of E. I. Du Pont de Nemours & Co.
Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-148 Kalpakjian Schmid Manufacturing Engineering and Technology Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006 Page 7-149 Kalpakjian Schmid Manufacturing Engineering and Technology
Figure 28.17 The sequence of operations in the fabrication of various structures by diffusion bonding and then superplastic forming of (originally) flat sheets. Sources: (a) After D. Stephen and S.J. Swadling. (b) and (c) Rockwell International Corp.
Page 7-150
17

Manufacturing Engineering and Technolog

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manufacturing Engineering and Technolog

Uploaded by

Copyright:

Available Formats

I Edition information

Manufacturing engineering and technology machining Preface()

3 what is new in the 4th edition:

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

III Suitable audience

IV About the authors

Mechanical Manufacturing Industrial Aerospace Metallurgical() and materials engineering

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

IV About the authors

Part IV: Material-removal processes and machines

Part IV: Why need the material-removal processes

Dr. Steven R. Schmid is:

Figure 1 Schematic illustration of a sand mold, showing various features

Figure 3. Bending process

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Examples of Parts Produced Using the Machining Processes in the Chapter

Examples of Milling Cutters and Operations

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Example of Part Produced on a CNC Milling Machine

Conventional and Climb Milling

Summary of Milling Parameters and Formulas

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Effects of Insert Shapes Face-Milling Cutter

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Effect of Lead Angle

Cutter and Insert Position in Face Milling

Cutters for Different Types of Milling

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Other Milling Operations and Cutters

Capacities and Maximum Workpiece Dimensions for Machine Tools

Note: Larger capacities are available for special applications.

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

Kalpakjian Schmid Manufacturing Engineering and Technology

Jiancheng Miao, Department of mechanical, Shazhou Tech, Source: Prentice-Hall, 2006

TABLE 23.3 Approximate Cost of Selected Tools for Machining*