Machining technology: machine tools and operations

672 Pages·2008·18.04 MB·English

by  Helmi A. Youssef, Hassan El-Hofy

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Library of Congress Cataloging-in-Publication Data
Youssef, Helmi A.
Machining technology : machine tools and operations / Helmi A. Youssef, Hassan El-Hofy.
p. cm.
Includes bibliographical references and index.
ISBN 978-1-4200-4339-6 (hardback : alk. paper) 1. Machining. 2. Machine-tools. I. El-Hofy, Hassan.
II. Title.
TJ1185.Y68 2008
671.3’5--dc22 2008008302
Visit the Taylor & Francis Web site at
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To our grandsons and granddaughters,
Omar, Youssef, Nour, Anourine, Fayrouz, and Yousra
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Contents
Preface ............................................................................................................................................xix
Acknowledgments ........................................................................................................................ xxiii
Editors ............................................................................................................................................xxv
List of Symbols ............................................................................................................................xxvii
List of Acronyms ....................................................................................................................... xxxiii
Chapter 1 Machining Technology .................................................................................................1
1.1 Introduction ...............................................................................................................................1
1.2 History of Machine Tools .........................................................................................................1
1.3 Basic Motions in Machine Tools ...............................................................................................5
1.4 Aspects of Machining Technology ...........................................................................................5
1.4.1 Machine Tool .................................................................................................................6
1.4.2 Workpiece Material .......................................................................................................9
1.4.3 Machining Productivity .................................................................................................9
1.4.4 Accuracy and Surface Integrity ................................................................................... 10
1.4.5 Product Design for Economical Machining ................................................................ 10
1.4.6 Environmental Impacts of Machining ........................................................................ 10
1.5 Review Questions .................................................................................................................... 10
References ........................................................................................................................................ 10
Chapter 2 Basic Elements and Mechanisms of Machine Tools .................................................. 11
2.1 Introduction ............................................................................................................................. 11
2.2 Machine Tool Structures ......................................................................................................... 13
2.2.1 Light- and Heavy-weight Constructions ...................................................................... 17
2.3 Machine Tool Guideways ........................................................................................................ 18
2.3.1 Sliding Friction Guideways ......................................................................................... 18
2.3.2 Rolling Friction Guideways ......................................................................................... 21
2.3.3 Externally Pressurized Guideways ..............................................................................22
2.4 Machine Tool Spindles ............................................................................................................23
2.4.1 Spindle Bearings .........................................................................................................23
2.4.2 Selection of Spindle-Bearing Fit .................................................................................25
2.4.3 Sliding Friction Spindle Bearing .................................................................................27
2.5 Machine Tool Drives ...............................................................................................................28
2.5.1 Stepped Speed Drives ..................................................................................................28
2.5.1.1 Belting ...........................................................................................................28
2.5.1.2 Pick-Off Gears ..............................................................................................30
2.5.1.3 Gearboxes ......................................................................................................30
2.5.1.4 Stepping of Speeds According to Arithmetic Progression ........................... 31
2.5.1.5 Stepping of Speeds According to Geometric Progression ............................ 32
2.5.1.6 Kinetic Calculations of Speed Gearboxes .................................................... 35
2.5.1.7 Application of Pole-Changing Induction Motors .......................................... 35
2.5.1.8 Feed Gearboxes ............................................................................................ 37
2.5.1.9 Preselection of Feeds and Speeds ................................................................. 39
vii
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viii Contents
2.5.2 Stepless Speed Drives .................................................................................................40
2.5.2.1 Mechanical Stepless Drives .........................................................................40
2.5.2.2 Electrical Stepless Speed Drive ................................................................... 42
2.5.2.3 Hydraulic Stepless Speed Drive ................................................................... 43
2.6 Planetary Transmission ..........................................................................................................44
2.7 Machine Tool Motors ............................................................................................................. 45
2.8 Reversing Mechanisms ........................................................................................................... 45
2.9 Couplings and Brakes .............................................................................................................46
2.10 Reciprocating Mechanisms ....................................................................................................48
2.10.1 Quick-Return Mechanism ...........................................................................................48
2.10.2 Whitworth Mechanism ................................................................................................50
2.10.3 Hydraulic Reciprocating Mechanism .........................................................................50
2.11 M aterial Selection and Heat Treatment of Machine Tool Components ................................. 51
2.11.1 Cast Iron ...................................................................................................................... 51
2.11.2 Steels ............................................................................................................................ 52
2.12 Testing of Machine Tools ....................................................................................................... 53
2.13 Maintenance of Machine Tools .............................................................................................. 55
2.13.1 Preventive Maintenance ..............................................................................................56
2.13.2 Corrective Maintenance ..............................................................................................56
2.13.3 Reconditioning ............................................................................................................56
2.14 Review Questions ................................................................................................................... 57
References ........................................................................................................................................ 57
Chapter 3 General-Purpose Machine Tools ................................................................................ 59
3.1 Introduction ............................................................................................................................ 59
3.2 Lathe Machines and Operations ............................................................................................. 59
3.2.1 Turning Operations ...................................................................................................... 59
3.2.2 Metal Cutting Lathes ...................................................................................................60
3.2.2.1 Universal Engine Lathes ...............................................................................60
3.2.2.2 Other Types of General-Purpose Metal Cutting Lathes ...............................69
3.3 Drilling Machines and Operations ......................................................................................... 70
3.3.1 Drilling and Drilling Allied Operations ..................................................................... 70
3.3.1.1 Drilling Operation ......................................................................................... 70
3.3.1.2 Drilling Allied Operations ............................................................................ 71
3.3.2 General-Purpose Drilling Machines ........................................................................... 74
3.3.2.1 Bench-Type Sensitive Drill Presses .............................................................. 74
3.3.2.2 Upright Drill Presses ..................................................................................... 74
3.3.2.3 Radial Drilling Machines ............................................................................. 76
3.3.2.4 Multispindle Drilling Machines .................................................................... 76
3.3.2.5 Horizontal Drilling Machines for Drilling Deep Holes ...............................77
3.3.3 Tool Holding Accessories of Drilling Machines .........................................................77
3.3.4 Work-Holding Devices Used on Drilling Machines ................................................... 79
3.4 Milling Machines and Operations .......................................................................................... 82
3.4.1 Milling Operations ...................................................................................................... 82
3.4.1.1 Peripheral Milling ......................................................................................... 82
3.4.1.2 Face Milling ..................................................................................................84
3.4.2 Milling Cutters ............................................................................................................84
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Contents ix
3.4.3 General-Purpose Milling Machines ...........................................................................86
3.4.3.1 Knee-Type Milling Machines .......................................................................86
3.4.3.2 Vertical Bed-Type Milling Machines............................................................88
3.4.3.3 Planer-Type Milling Machine .......................................................................88
3.4.3.4 Rotary-Table Milling Machines .................................................................... 89
3.4.4 Holding Cutters and Workpieces on Milling Machines .............................................90
3.4.4.1 Cutter Mounting ............................................................................................90
3.4.4.2 Workpiece Fixturing ..................................................................................... 91
3.4.5 Dividing Heads ...........................................................................................................94
3.4.5.1 Universal Dividing Heads .............................................................................94
3.4.5.2 Modes of Indexing ........................................................................................95
3.5 Shapers, Planers, and Slotters and Their Operations ..............................................................99
3.5.1 Shaping, Planing, and Slotting Processes ....................................................................99
3.5.1.1 Determination of v in Accordance with the Machine Mechanism .......... 101
cm
3.5.2 Shaper and Planer Tools ............................................................................................ 102
3.5.3 Shapers, Planers, and Slotters.................................................................................... 103
3.5.3.1 Shapers ........................................................................................................ 103
3.5.3.2 Planers ......................................................................................................... 105
3.5.3.3 Slotters......................................................................................................... 107
3.6 Boring Machines and Operations ........................................................................................ 107
3.6.1 Boring ........................................................................................................................ 107
3.6.2 Boring Tools .............................................................................................................. 108
3.6.2.1 Types of Boring Tools ................................................................................. 108
3.6.2.2 Materials of Boring Tools ........................................................................... 109
3.6.3 Boring Machines ....................................................................................................... 109
3.6.3.1 General-Purpose Boring Machines............................................................. 109
3.6.3.2 Jig Boring Machines ................................................................................... 110
3.7 Broaching Machines and Operations .................................................................................... 111
3.7.1 Broaching .................................................................................................................. 111
3.7.1.1 Advantages and Limitations of Broaching ................................................. 112
3.7.2 The Broach Tool ........................................................................................................ 113
3.7.2.1 Tool Geometry and Conf guration .............................................................. 113
3.7.2.2 Broach Material .......................................................................................... 116
3.7.2.3 Broach Sharpening ...................................................................................... 116
3.7.3 Broaching Machines .................................................................................................. 116
3.7.3.1 Horizontal Broaching Machines ................................................................. 117
3.7.3.2 Vertical Broaching Machines...................................................................... 118
3.7.3.3 Continuous Horizontal Surface Broaching Machines ................................ 118
3.8 Grinding Machines and Operations ...................................................................................... 119
3.8.1 Grinding Process ....................................................................................................... 119
3.8.2 Grinding Wheels ....................................................................................................... 122
3.8.2.1 Manufacturing Characteristics of Grinding Wheels .................................. 122
3.8.2.2 Grinding Wheel Geometry ......................................................................... 127
3.8.2.3 Mounting and Balancing of Grinding Wheels and Safety Measures ......... 127
3.8.2.4 Turning and Dressing of Grinding Wheels ................................................. 130
3.8.3 Grinding Machines .................................................................................................... 131
3.8.3.1 Surface Grinding Machines and Related Operations ................................. 132
3.8.3.2 External Cylindrical Grinding Machines and Related Operations ............ 133
3.8.3.3 Internal Grinding Machines and Related Operations ................................. 136
3.8.3.4 Centerless Grinding Machines and Related Operations ............................. 137
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