Manufacturing Technology Vol 2

598 Pages·2018·14.641 MB·English

by  Rao

Manufacturing
technology
Volume II
Metal Cutting and Machine Tools
Fourth Edition
MT4e-V2_00_Prelims.indd 1 7/13/2018 4:48:50 PM
About The Author
P N Rao received his BE degree in Mechanical Engineering from the Government
Engineering College, Anantapur (Sri Venkateswara University, Tirupati), in 1970,
ME degree from Birla Institute of Technology and Science, Pilani, in 1973 and PhD
from the Indian Institute of Technology, Delhi, in 1981.
Presently, he is working as a Professor in the University of Northern Iowa, Cedar
Falls, USA, in the Department of Technology, since Fall of 2001. Earlier he worked
in the Indian Institute of Technology, New Delhi, from 1975 till 1997, the final
position being as a Professor in the Mechanical Engineering Department between
1990 and 1997. He has also taught at the MARA University of Technology, Shah
Alam, Malaysia, between 1995 and 2001. Prior to joining IIT Delhi, he worked in the
Birla Institute of Technology and Science, Pilani, for a period of two years. He has conducted post-doctoral
research in UMIST, Manchester, UK (1980–1981), and Loughborough University of Technology, UK (1989).
His active areas of research are Manufacturing Engineering, Design Engineering, Sustainable
Manufacturing, CAD/CAM, CIM, Tool design and MEMS, and Nano education. He is the author and
co-author of more than 250 papers, published and presented in national and international journals and
conferences, respectively.
He also has wide interaction with the industry through the process of consultancy work. He conducts
continuing education programmes on various aspects related to modern manufacturing. He has received a
number of grants from various bodies to support his research activities.
He has authored three books, all published by McGraw-Hill Education (India).
● Manufacturing Technology, Volume 1: Foundry, Forming and Welding, 5e
● Computer Aided Manufacturing, 1e (with Kundra and Tewari as co-authors)
● CAD/CAM: Principles and Applications, 3e
He has also worked as a co-editor of Emerging Trends in Manufacturing (Proceedings of the 12th All India
Machine Tool Design and Research Conference, 1986) published by McGraw-Hill Education (India).
Dr P N Rao’s biographical information has appeared in Marquis Who’s Who in The World, Marquis Who’s
Who in Finance and Industry, Marquis Who’s Who in Science and Engineering, Marquis Who’s Who in
America, Marquis Who’s Who in American Education, and Who’s Who in Asia and the Pacific Nations.
MT4e-V2_00_Prelims.indd 2 7/13/2018 4:48:53 PM
Manufacturing
technology
Volume II
Metal Cutting and Machine Tools
Fourth Edition
P N Rao
Professor
Department of Technology
University of Northern Iowa
Cedar Falls
USA
McGraw Hill Education (India) Private Limited
CHENNAI
McGraw Hill Education Offices
Chennai New York St Louis San Francisco Auckland Bogotá Caracas
Kuala Lumpur Lisbon London Madrid Mexico City Milan Montreal
San Juan Santiago Singapore Sydney Tokyo Toronto
MT4e-V2_00_Prelims.indd 3 7/13/2018 4:48:53 PM
McGraw Hill Education (India) Private Limited
Published by McGraw Hill Education (India) Private Limited
444/1, Sri Ekambara Naicker Industrial Estate, Alapakkam, Porur, Chennai - 600 116
Manufacturing Technology—Metal Cutting and Machine Tools, 4e (Volume II)
Copyright © 2019 by McGraw Hill Education (India) Private Limited.
No part of this publication may be reproduced or distributed in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise or stored in a database or retrieval system without the prior written permission of the publishers. The program
listings (if any) may be entered, stored and executed in a computer system, but they may not be reproduced for publication.
This edition can be exported from India only by the publishers,
McGraw Hill Education (India) Private Limited
Print Edition:
ISBN-13: 978-93-5316-052-4
ISBN-10: 93-5316-052-9
E-Book Edition:
ISBN-13: 978-93-5316-053-1
ISBN-10: 93-5316-053-7
1 2 3 4 5 6 7 8 9 D101417 22 21 20 19 18
Printed and bound in India.
Director—Science & Engineering Portfolio: Vibha Mahajan
Senior Portfolio Manager—Science & Engineering: Hemant K Jha
Associate Portfolio Manager —Science & Engineering: Vaishali Thapliyal
Senior Manager—Content Development: Shalini Jha
Senior Content Developer: Ruhhi Ralhan
Production Head: Satinder S Baveja
Copy Editor: Taranpreet Kaur
Assistant Manager—Production: Suhaib Ali
General Manager—Production: Rajender P Ghansela
Manager—Production: Reji Kumar
Information contained in this work has been obtained by McGraw Hill Education (India), from sources believed to be reliable. However,
neither McGraw Hill Education (India) nor its authors guarantee the accuracy or completeness of any information published herein,
and neither McGraw Hill Education (India) nor its authors shall be responsible for any errors, omissions, or damages arising out
of use of this information. This work is published with the understanding that McGraw Hill Education (India) and its authors are
supplying information but are not attempting to render engineering or other professional services. If such services are required, the
assistance of an appropriate professional should be sought.
Typeset at The Composers, 260, C.A. Apt., Paschim Vihar, New Delhi 110 063 and printed and bound in India at
Cover Printer:
Cover Designer: The Computer Minds
Cover Image Source: Panksvatouny/Shutterstock
Visit us at: www.mheducation.co.in
Write to us at: [email protected]
CIN: U22200TN1970PTC111531
Toll Free Number: 1800 103 5875
MT4e-V2_00_Prelims.indd 4 7/13/2018 4:48:54 PM
DeDicateD to
My Parents, Suramma and Kondala Rayudu
MT4e-V2_00_Prelims.indd 5 7/13/2018 4:48:54 PM
MT4e-V2_00_Prelims.indd 6 7/13/2018 4:48:54 PM
Contents
Preface to the Fourth Edition xvii
Preface to the First Edition xix
Chapter 1 Introduction 1.1–1.5
1.1 Introduction to Material Removal Processes 1.1
1.2 Variety of Machine Tools 1.2
1.3 Automation 1.4
Chapter 2 Metal Cutting 2.1–2.72
Objectives 2.1
2.1 Introduction 2.1
2.2 Chip Formation 2.3
2.2.1 Discontinuous Chip 2.3
2.2.2 Continuous Chip 2.4
2.2.3 Continuous Chip with BUE 2.4
2.2.4 BUE 2.5
2.3 Shear Zone 2.5
2.4 Orthogonal Cutting 2.6
2.4.1 Mechanics of Orthogonal Metal Cutting 2.7
2.5 Shear Angle and its Relevance 2.17
2.6 Cutting Tool Geometry 2.18
2.6.1 ASA System 2.19
2.6.2 Orthogonal Rake System (ORS) 2.19
2.6.3 ISO System or Normal Rake System (NRS) 2.22
2.6.4 Significance of Various Tool Angles 2.22
2.7 Dynamometers 2.23
2.7.1 Sensing Technologies Used in Dynamometers 2.24
2.7.2 Two-component Dynamometer Design 2.24
2.8 Cutting Tool Materials 2.25
2.8.1 Carbon Tool Steels 2.26
2.8.2 High Speed Steel 2.26
2.8.3 Cast Cobalt Alloys 2.27
2.8.4 Cemented Carbides 2.28
2.8.5 Coated Carbides 2.31
MT4e-V2_00_Prelims.indd 7 7/13/2018 4:48:54 PM
viii
Contents
2.8.6 Ceramics 2.33
2.8.7 Diamond 2.34
2.8.8 Cubic Boron Nitride (CBN) 2.34
2.9 Thermal Aspects 2.36
2.9.1 Tool Work Thermocouple 2.36
2.9.2 Analytical Determination of Temperature in Metal Cutting 2.37
2.10 Tool Wear and Tool Life 2.39
2.10.1 Tool Life 2.42
2.10.2 Tool Life Equation 2.44
2.10.3 Machinability 2.45
2.10.4 Variables Affecting Tool Life 2.45
2.11 Surface Finish 2.46
2.11.1 Ideal Surface Finish in Turning 2.46
2.12 Cutting Fluids 2.48
2.13 Empirical and Analytical Determination of Cutting Forces 2.52
2.14 Economics 2.53
Summary 2.61
Questions 2.62
Problems 2.64
Multiple Choice Questions 2.69
Answers to MCQs 2.71
Case Study: Machining 2.71
Chapter 3 Machine Tools 3.1–3.25
Objectives 3.1
3.1 Introduction 3.1
3.2 Classification of Machine Tools 3.2
3.3 Generating and Forming 3.3
3.4 Methods of Generating Surfaces 3.4
3.5 Accuracy and Finish Achievable 3.7
3.6 Basic Elements of Machine Tools 3.9
3.7 Support Structures 3.9
3.8 Power Transmission 3.11
3.9 Actuation Systems 3.15
3.10 Guideways 3.17
3.10.1 Types of Slideways 3.17
3.10.2 Linear Motion Elements 3.21
3.11 General Work Holding Methods 3.22
Summary 3.22
Questions 3.23
Multiple Choice Questions 3.23
Answers to MCQs 3.25
MT4e-V2_00_Prelims.indd 8 7/13/2018 4:48:54 PM
ix
Contents
Chapter 4 Centre Lathe 4.1–4.47
Objectives 4.1
4.1 Introduction 4.1
4.2 Constructional Features of a Centre Lathe 4.2
4.2.1 Lathe Specifications 4.4
4.3 Aids for Support and Location 4.4
4.4 Cutting Tools 4.10
4.4.1 Cutting Tool Geometry 4.10
4.4.2 Different Types of Tools Used 4.12
4.4.3 Errors in Tool Setting 4.15
4.4.4 Types of Tool Posts 4.16
4.4.5 Chip Control 4.16
4.5 Operations Performed in a Centre Lathe 4.17
4.5.1 Turning 4.17
4.5.2 Facing 4.17
4.5.3 Knurling 4.18
4.5.4 Parting 4.19
4.5.5 Drilling 4.19
4.5.6 Boring 4.20
4.6 Taper Turning Methods 4.20
4.7 Thread Cutting Methods 4.25
4.8 Special Attachments 4.29
4.8.1 Milling Attachment 4.29
4.8.2 Grinding Attachment 4.29
4.8.3 Copy Turning Attachment 4.29
4.8.4 Radius Turning Attachment 4.30
4.9 Machining Time and Power Estimation 4.31
4.10 Typical Setups 4.38
Summary 4.40
Questions 4.41
Problems 4.42
Multiple Choice Questions 4.44
Answers to MCQs 4.45
Case Study: Process Planning 4.46
Chapter 5 Special Purpose Lathes 5.1–5.25
Objectives 5.1
5.1 Limitations of a Centre Lathe 5.1
5.2 Capstan and Turret Lathes 5.2
5.2.1 Typical Tool Layouts 5.6
5.3 Automatic Lathes 5.11
5.3.1 Classification 5.11
5.3.2 Cutting off Machines 5.13
MT4e-V2_00_Prelims.indd 9 7/13/2018 4:48:54 PM
x
Contents
5.3.3 Swiss Type Automatics or Sliding Headstock Automatics 5.13
5.3.4 Automatic Screw Machines 5.14
5.3.5 Multiple Spindle Automatics 5.14
5.4 Tooling Layout and Cam Design for Automatic Lathes 5.17
5.4.1 Tool Layouts 5.17
5.4.2 Cam Design 5.20
Summary 5.23
Questions 5.23
Multiple Choice Questions 5.24
Answers to MCQs 5.25
Chapter 6 Reciprocating Machine Tools 6.1–6.22
Objectives 6.1
6.1 Introduction 6.1
6.2 Shaper 6.1
6.2.1 Shaper Construction 6.2
6.2.2 Quick Return Motion 6.4
6.2.3 Mechanical Feed Drive 6.6
6.2.4 Shaper Specifications 6.6
6.2.5 Types of Shapers 6.6
6.2.6 Hydraulic Shaper 6.7
6.2.7 Work Holding in Shaping 6.8
6.2.8 Cutting Tools Used 6.8
6.2.9 Shaping Time and Power Estimation 6.8
6.3 Planing Machine (Planer) 6.11
6.3.1 Types of Planers 6.14
6.3.2 Planer Specifications 6.14
6.3.3 Planing Time Estimation 6.15
6.4 Slotting Machine (Slotter) 6.17
6.5 Comparison of Reciprocating Machine Tools 6.18
Summary 6.19
Questions 6.19
Problems 6.20
Multiple Choice Questions 6.21
Answers to MCQs 6.22
Chapter 7 Milling 7.1–7.39
Objectives 7.1
7.1 Introduction 7.1
7.2 Types of Milling Machines 7.2
7.2.1 Knee and Column Milling Machine 7.2
7.2.2 Bed Type Milling Machine 7.4
MT4e-V2_00_Prelims.indd 10 7/13/2018 4:48:54 PM