Precision Engineering PDF
Preview Precision Engineering
(cid:2)(cid:3)(cid:4)(cid:5)(cid:6)(cid:7)(cid:6)(cid:8)(cid:9) (cid:2)(cid:3)(cid:4)(cid:5)(cid:3)(cid:2)(cid:2)(cid:6)(cid:5)(cid:3)(cid:4) (cid:2)(cid:3)(cid:4)(cid:5)(cid:6)(cid:7)(cid:6)(cid:8)(cid:9) (cid:2)(cid:3)(cid:4)(cid:5)(cid:3)(cid:2)(cid:2)(cid:6)(cid:5)(cid:3)(cid:4) V. C. Venkatesh Faculty of Engineering & Technology Multimedia University Melaka, Malaysia Sudin Izman Faculty of Mechanical Engineering Malaysian University of Technology Johor Bahru, Malaysia Tata McGraw-Hill Publishing Company Limited NEW DELHI McGraw-Hill Offices New Delhi 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 Copyright © 2007 by Tata McGraw-Hill Publishing Company Limited. All rights reserved. Manufactured in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written permission of the publisher. 0-07-154828-9 The material in this eBook also appears in the print version of this title: 0-07-154827-0. All trademarks are trademarks of their respective owners. Rather than put a trademark symbol after every occurrence of a trademarked name, we use names in an editorial fashion only, and to the benefit of the trademark owner, with no intention of infringement of the trademark. Where such designations appear in this book, they have been printed with initial caps. McGraw-Hill eBooks are available at special quantity discounts to use as premiums and sales promotions, or for use in corporate training programs. For more information, please contact George Hoare, Special Sales, at [email protected] or (212) 904-4069. 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Under no circumstances shall McGraw-Hill and/or its licensors be liable for any indirect, incidental, special, punitive, consequential or similar damages that result from the use of or inability to use the work, even if any of them has been advised of the possibility of such damages. This limitation of liability shall apply to any claim or cause whatsoever whether such claim or cause arises in contract, tort or otherwise. DOI: 10.1036/0071548270 Professional Want to learn more? We hope you enjoy this McGraw-Hill eBook! If you’d like more information about this book, its author, or related books and websites, please click here. To My Family: Wife Gita, Sons—Dr. Vasisht Venkatesh & his Wife Shruti and Kaushik Venkatesh & Grandson Rohan Venkatesh, all from Nevada, USA —V.C. VENKATESH TO My Parents and Family —IZMAN SUDIN This page intentionally left blank (cid:2)(cid:3)(cid:4)(cid:5)(cid:6)(cid:7)(cid:4) This book owes its inspiration to the M Sc Programme in precision engineering initiated in GINTIC Institute of Technology, Singapore by Cranfield University lecturers—Prof. P.A. McKeown, Prof.J.Corbett, and Prof. W. Wills Moren during the author’s tenure at NTU, Singapore during 1993–97. This was further enhanced by the author’s CIRP and ASPE membership and his attendance of their conferences. However, the main push was the purchase of Precitech’s ultra-precision turning and grinding (UPTG) machine whose working needed to be understood. The need for high stiffness brought about by hydrostatic and aerostatic bearings made the author work in this area while introducing the course at the undergraduate level in NTU and later for seven years in UTM, Johor Bahru, Malaysia. The author’s success with the publication of his first book Experimental techniques in metal cutting in 1981, followed by a 2nd Edition in 1987 strengthened his resolve to write on precision engineering. This book is divided into eight chapters: Chapter 1 is an introduction to precision engineering. It starts with McKeown’s scale diagram fitting microtechnology and nanotechnology with some predictions. Accuracy and precision have been clearly distinguished with the help of target shooting on a bull’s eye circle. Taniguchi’s diagram of four classes of machining and his table of optical, mechanical and electronic products are shown. Chapter 2 deals with all precision cutting tool materials, with special emphasis on diamond tools. There is an introduction to Miller indices with crystallographic planes of single crystal diamonds. Their orientation for use as cutting tools especially for ultra-precision diamond turning is discussed. CVD and PVD coatings are also highlighted. Chapter 3 deals with the mechanics of materials cutting. Merchant’s mechanics of metal cutting with all derivations is discussed, including the strain equation that was modified by Townend. Since diamond turning now involves turning of non-metals like silicon and glass, this chapter uses the phrase—materials cutting. The work of Scattergood and his colleagues is presented here. Copyright © 2007 by Tata McGraw-Hill Publishing Company Limited. Click here for terms of use. (cid:2)(cid:3)(cid:3)(cid:3) (cid:4)(cid:5)(cid:6)(cid:7)(cid:8)(cid:9)(cid:6) Chapter 4 is on advances in precision grinding and gives details of abrasives and their classification when mounted on wheels. This chapter discusses ductile mode grinding and other well known machine tools which combine ultra-precision turning and grinding options. Chapter 5 on ultra-precision machine elements gives an introduction to elements that constitute UPTG machines. Bed way materials and their shapes are described. Drive systems comprising of nut and screw, friction and linear motor drives are discussed. There is also an introduction to preferred numbers. Chapter 6 discusses mostly hydrostatic bearings widely used in UPTG machines. However, rolling elements are also highlighted since Toshiba has used them very successfully in their UPTG machines. Hydrodynamic bearings are included in order to understand hybrid hydrostatic bearings better. Chapter 7 discusses gas lubricated bearings that are sometimes better known as aerostatic bearings, which are used for spindles. Spindle design is discussed with examples. Gas bearings are sometimes used for slide ways and their advantages, disadvantages and maintenance requirements are highlighted in a table. Chapter 8 is the final chapter and deals with MEMS (Microelectro-mechanical Systems). Since silicon is the material that is used widely for MEMS its inclusion in this book is quite appropriate. Bulk and surface micromachining and the LIGA process are discussed. The last part discusses clean rooms and their design. The late Dr. M.E. Merchant always emphasized that manufacturing is a source of wealth generation. High-precision manufacturing is even more lucrative since it produces value added products that use less material but more design and intricate manufacturing processes. Hopefully this book is a small contribution to that goal. It is hoped that the course in precision engineering will be introduced in many universities particularly in India and SE Asia and hopefully world wide, and that this book will serve to help lecturers and students alike in understanding this fascinating area, vital to developing countries. V.C. VENKATESH S. IZMAN (cid:6)(cid:7)(cid:8)(cid:9)(cid:10)(cid:11)(cid:12)(cid:4)(cid:13)(cid:14)(cid:4)(cid:15)(cid:4)(cid:9)(cid:16)(cid:17) I would like to thank industries/institutions that supported me in my research that resulted in many pictures and information used in this book: • Widia (India), Bangalore (now known as Kennametal Widia), which helped me in developing the TiC-coated TiC tool. They were kind enough to furnish many cutting tools and micrographs. • Central Manufacturing Technology Institute, Bangalore for lending their Machine Tools Design Handbook, giving details of their clean rooms in the Precision Engineering Centre and their Diamond Turning Machine Tool (India’s first). • Kennametal Inc., Latrobe, USA for funding my work at Tennessee Technological University (1993–1998) and furnishing me with the tools and micrographs while I was with the University Technology Malaysia, Johor Bahru. I am also grateful for their help in developing the Bondless Diamond Grinding Wheel. • Lecturers from Cranfield University—Prof. McKeown, Prof. Corbett and Prof. Wills Moren, who conducted the M Sc course in precision engineering at Nanyang Technological University, Singapore and provided us with copious notes. • Precitech Inc., Keene, NH, USA which I visited several times during my trips to the US. We also bought their machine (Optimum 2800-X & Z axis) in 1996 while working with Nanyang Technological University, Singapore. My special thanks go to Mr. Dennis Keating for the personal discussions we had in Singapore, Malaysia and Keene, NH and also for being kind enough to provide pictures of their machines and products. • Moore Inc., Keene, NH, USA, which I visited several times during my trips to the US and whose machine (Nanotech 250UPL-X & Z axis) was evaluated while I was with University of Technology Malaysia and which will be installed shortly. My special thanks go to Mr. Len Chaloux, CEO, for personal discussions and for providing me pictures of their machines and products. My thanks also go to Mr. Gavin Chapman for discussions we had in Singapore and Malaysia. Copyright © 2007 by Tata McGraw-Hill Publishing Company Limited. Click here for terms of use.
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