CRC_43390_FM.indd i 3/25/2008 5:13:23 PM CRC_43390_FM.indd i 3/25/2008 5:13:25 PM CRC_43390_FM.indd i 3/25/2008 5:13:25 PM CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2008 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Printed in the United States of America on acid-free paper 10 9 8 7 6 5 4 3 2 1 International Standard Book Number-13: 978-1-4200-4339-6 (Hardcover) This book contains information obtained from authentic and highly regarded sources Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the valid- ity of all materials or the consequences of their use. 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CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For orga- nizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. 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 http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com CRC_43390_FM.indd iv 3/25/2008 5:13:25 PM To our grandsons and granddaughters, Omar, Youssef, Nour, Anourine, Fayrouz, and Yousra CRC_43390_FM.indd v 3/25/2008 5:13:25 PM CRC_43390_FM.indd vi 3/25/2008 5:13:26 PM 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 CRC_43390_FM.indd vi 3/25/2008 5:13:26 PM 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 CRC_43390_FM.indd vi 3/25/2008 5:13:26 PM 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 CRC_43390_FM.indd ix 3/25/2008 5:13:26 PM