10. Surface Finish and Integrity 10.1 Introduction 10.2 Measurement of Surface Finish 10.3 Surface Finish in Turning and Boring 10.4 Surface Finish in Milling 10.5 Surface Finish in Drilling and Reaming 10.6 Surface Finish in Grinding 10.7 Residual Stresses in Machined Surfaces
484 489 493 499 499
551 551 552 558 562 565 566 568
xvi
Contents
10.8 White Layer Formation 10.9 Surface Burn in Grinding 10.10 Examples 10.11 Problems References
569 570 571 573 574
11.
Machinability of Materials 11.1 Introduction 11.2 Machiikability Criteria, Tests, and Indices 11.3 Chip Control 11.4 Burr Formation and Control 11.5 Machinability of Engineering Materials References
577 577 578 582 588 591 611
12.
Machining Dynamics 12.1 Introduction 12.2 Vibration Analysis Methods 12.3 Vibration of Discrete (Lumped Mass) Systems 12.4 Types of Machine Tool Vibration 12.5 Forced Vibration 12.6 Self-Excited Vibrations (Chatter) 12.7 Chatter Prediction 12.8 Vibration Control 12.9 Active Vibration Control 12.10 Examples 12.11 Problems References
Machining Economics and Optimization 13.1 Introduction 13.2 Role of a Computerized Optimization System 13.3 Economic Considerations 13.4 Optimization of Machining Systems — Basic Factors 13.5 Optimization of Machining Conditions 13.6 Formulation of the Optimization Problem 13.7 Optimization Techniques 13.8 Examples 13.9 Problems References
705 705 707 708 710 711 712 719 741 758 760
14.
Cutting Fluids 14.1 Introduction 14.2 Types of Cutting Fluids 14.3 Coolant Application 14.4 Filtering 14.5 Condition Monitoring and Waste Treatment 14.6 Health and Safety Concerns 14.7 Dry and Near-Dry Machining Methods
767 767 768 771 773 778 779 781
Contents
xvii
14.8 Test Procedure for Cutting Fluid Evaluation References
783 783
15. High Throughput and Agile Machining 15.1 Introduction 15.2 High Throughput Machining 15.3 Agile Machining Systems 15.4 Tooling and Fixturing 15.5 Materials Handling Systems References
787 787 787 789 791 800 802
16. Design for Machining 16.1 Introduction 16.2 Machining Costs 16.3 General Design for Machining Rules 16.4 Special Considerations for Specific Types of Equipment and Operations 16.5 CAPP and DFM Programs 16.6 Part Quality Modeling 16.7 Examples References