Tool and Manufacturing Engineers Handbook Volume I – Machining

Tool and Manufacturing Engineers Handbook Volume I – Machining
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Thomas J. Drozda
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Tool and Manufacturing Engineers Handbook Volume I – Machining
A reference book for manufacturing engineers, managers, and technicians
Fourth Edition
Thomas J. Drozda, PE, CMfgE
Editor-In-Chief
Charles Wick, CMfgE
Managing Editor
CONTENTS
VOLUME I-MACHINING
Symbols and Abbreviations xi
Principles of Metalcutting and Machinability 1-1
Tolerance Control 2-1
Cutting Tool Materials . 3-1
Cutting Fluids and Industrial Lubricants .
Sawing . 6-1
Broaching. Planing. Shaping and Slotting
Turning and Boring 8-1
Drilling. Reaming and Related Processes 9-1
Milling . 10-1
Grinding 11-1
Threading 12-1
Gear and Spline Production
Nontraditional Machining 14-1
Multifunction Machines 15-1
Machine Loading and Unlaading 16-1
Machine Rebuilding 17-1
Safety and Noise Control .
Machine Controls 5-1
Index . 1-1
SYMBOLS AND
ABBREVIATIONS
The following is a list of symbols and abbreviations in general use throughout this volume. Supplementary and/or derived units,
symbols, and abbreviations which are peculiar to specific subject matter are listed within chapters.
A
A
AA
ABN
ABS
a-c
AC
ACC
ACD
A/cm2
ACO
A/D
AFM
AFMDC
AGMA
A/in.2
AIS1
Al
ALGOL
A1203
ANSI
API
APT
ASLE
ASM
ASME
ASP
ASTM
AUTOSPOT
AWG
Ampere
Arithmetic average
Amber boron nitride
Acrylonitrile butadiene styrene
Alternating current
Adaptive control
Adaptive control for constraint
Annealed cold drawn
Ampere per square centimeter
Adaptive control for optimization
Analog/digital
Abrasive flow machining
Air Force Machinability Data Center
American Gear Manufacturers Association
Ampere per square inch
American Iron and Steel Institute
Aluminum
Algorithmic language
Aluminum oxide (alumina)
American National Standards Institute
American Petroleum Institute
Automatic programming tool
American Society of Lubrication Engineers
American Society for Metals
American Society of Mechanical Engineers
Antisegregation process
American Society for Testing and Materials
Automatic system for positioning of tools
American wire gauge
B
BASIC
B,C
BCD
Be’
Bhn
BOD
B/P
BTR
BTU
BTU/in,2
BUE
BZN
Beginner’s all-purpose symbolic instruction
code
Boron carbide
Binary coded data
Baume’ specific gravity scale
Brinell hardness
Biological oxidation demand
Blueprint
Behind the tape reader
British thermal unit
British thermal unit per square inch
Built-up edge
Borazon brand cubic boron nitride (G. E.)
c
c
CAD/CAM
cal
CAL
cal/cm3
cal/ in.3
CAM]
CAPP
Cb
CbC
CBN
cfm
CIMS
CL
cm
cmz
cm3 / A-s
CMfgE
cm2 / hr
cm2 / m
cm2 / min
cm3 / min
CMOS
cm/s
cm3 /s
CNC
co
co.
co
C02
COBOL
COD
COM
Corp.
CP
CPM
Cps
CPU
Cr
CRT
CSA
Cst
Ctbr
Cu
CVD
Coulomb, Celsius or carbon
Computer aided design/ Computer aided
manufacturing
Calorie
Conversional algebraic language
Calorie per cubic centimeter
Calorie per cubic inch
Coated Abrasive Manufacturers Institute
Computer aided process planning
Columbium
Columbium carbide
Cubic boron nitride
Cubic foot per minute
Computer integrated manufacturing system
Cutter location
Centimeter
Square centimeter
Cubic centimeter per ampere second
Certified manufacturing engineer
Square centimeter per hour
Square centimeter per meter
Square centimeter per minute
Cubic centimeter per minute
Complementary metal oxide semiconductor
Centimeter per second
Cubic centimeter per second
Computer numerical control
Cobalt
Company
Compliance officer
Carbon dioxide
Common Business Oriented Language
Chemical oxidation demand
Computer output microfilm
Corporation
Centipoise
Crucible Particle Metallurgy
Cycle per second
Central processing unit
Chromium
Cathode ray tube
Canadian Standards Association
Centistoke
Counterbore
Copper
Chemical vapor deposition
D
dB
d-c
DC
DCF
DCTL
DDA
DEC
deg or 0
diam
DIN
Div.
DNC
DRO
DTL
DX
Decibel
Direct current
Data communication
Discounted cash flow
Direct-coupled transistor logic
Digital differential analyzer
Digital Equipment Corp.
Degree
Diameter
Dcutscher Normenausschuss (German
Standards Organization)
Division
Direct numerical control
Digital readout
Diode transistor logic
Data transfer
E
E
EBG
EBM
EBW
ECD
ECDG
ECEA
ECG
ECH
ECM
ECP
ECT
ECVT
EDC
EDG
EDM
EDP
EDWC
EEM
EHD
EIA
ELP
EMD
EMM
EMT
EOB
EOP
EOT
EP
EPA
EPROM
Eq,
ER
ESCM
ESM
ESR
EVM
EXAPT
xii
Modulus of elasticity
Electrolytic belt grinding
Electron beam machining
Electron beam welding
Electrochemical deburring
Electrochemical discharge grinding
End cutting edge angle
Electrochemical grinding
Electrochemical honing
Electrochemical machining
Electrochemical polishing
Electrochemical turning
Electrochemical vibratory tumbling
Extended data comparison
Electrical discharge grinding
Electrical discharge machining
Electronic data processing
Electrical discharge wire cutting
Electrolytic end milling
Elastohydrodynamic
Electronic Industries Association
Electropolishing
Electromechanical drilling
Electromechanical machining
Electromechanical turning
End of block
End of program
End of tape
Extreme pressure
Environmental Protection Agency
Erasable programmable read only memory
Equation
Electro-Ream
F.lectro-Stream chemical milling
Electro-Stream miUing
Electroslag remelting
Electrovapor machining
Extended subst?t of APT
F-G-H
F
FCI
fd
FDX
FeC13
FIFO
Fig.
fpm
fps
fpt
FRN
FSK
ft
ft2
ft,
ft’ / hr
FTS
gal
gl cm3
GDM
GJ / m’
g/L
GP
GPa
GPAC
GPG
gpm
GPO
GPS
GR
GT
H
HAZ
HBM
HC1
HZCr04
HD
HDAC
HDM
HDO
HDX
Hf
HF
HfC
Hg
HI-E
HO hp hp/in, hp/ in.3/ min hr HZS4 HSS HTM H7 Fahrenheit Flux changes per inch Farad Full duplex Ferric chloride First in, first out Figure Foot per minute Foot per second Feed per tooth Feed rate number Frequency shift keying Foot Square foot Cubic foot Cubic foot per hour Full top skive Gallon Gram per cubic centimeter Glow discharge machining Giga Joule per cubic meter Gram per liter General purpose Giga pascal General purpose aqueous coolant Grain per gallon Gallon per minute General purpose oil General purpose soluble oil Grinding ratio Group technology Henry Heat-affected zone Horizontal boring machine Hydrochloric acid Chromic acid Heavy duty Heavy duty aqueous coolant Hydrodynamic machining Heavy duty oil Half duplex Hafnium Hone-Forming Hafnium carbide Mercury High efficiency Water Horsepower Horsepower per inch Horsepower per cubic inch per minute Hour Sulphuric acid High speed steel High technology materials Cycles per second I-J I Ic ID IGA in. or “ in.z in.’ in. /ft in.2/ft in.2/hr in.3/hr in. /in, in. -lbf in. /rein in,2/min in.3/min in.j rein/ in. in. jpass in. js 1/0 1P ipm ipr IRR IRS 1s0 JJ / cm~ JIC Current or Moment of inertia Inscribed circle or Integrated circuit Inside diameter Intergranular attack Inch Square inch Cubic inch Inch per linear foot Square inch per foot Square inch per hour Cubic inch per hour Inch per inch inch pound force Inch per minute Square inch per minute Cubic inch per minute Cubic inch per minute per inch Inch per pass Inch per second Input-output Index of performance or United Kingdom Standard Inch per minute Inch per revolution Internal rate of return Internal Revenue Service international Standards Organization Joule Joule per square centimeter Joint Industry Conference kc kg kg/ mm2 kg/mm3 kHz k] kN kN. m kohm kPa ksi kV kW kW/cm3/min Kilocycles Kilogram Kilogram per square millimeter Kilogram per cubic millimeter Kilohertz Kiloliter KiloNewton KiloNewton meter Kilo-ohm Kilopascal 1000 pounds per square inch Kilovolt Kilowatt Kilowatt per cubic centimeter per minute L Liter lb Pound mass lbf Pound force Ibf-ft Foot pound lbf) in. Pound force per inch lb/gal Pound mass per gallon lb/ in.’ Pound mass per cubic inch LBM Lid LD LED LH lin LMC L/rein LPM LS LSD LSI Laser beam machining Length to diameter Light duty Light emitting diode Left hand Linear Least material condition Liter per minute Lines per minute Low stress Least significant digit Large scale integration M m m2 m3 mA math man max MC MCR MCTI MCU MD MD] MFM Mg MgO m3/ hr MHz min MIS ml mm mm2 mm’ MMC mm3 / hr m/ min mm/m mm/min mm2 / min mm3 / min mm/ mm mm/pass mm/rev mm/s mmz / s mm3 ;/s mm3/s/mm Mn MnS Mo MODEM MOS MOSV Meter Square meter Cubic meter Milliampere Machine Manual Maximum Molybdenum carbide Master control relay Metal Cutting Tool Institute Machine control unit Medium duty Manual data input Magnetic field machining Magnesium Magnesium Oxide Cubic meter per hour Megahertz Minimum or Minute Management information system Milliliter Millimeter Square millimeter Cubic millimeter Maximum material condition Cubic millimeter per hour Meter per minute Millimeter per linear meter Millimeter per minute Square millimeter per minute Cubic millimeter per minute Millimeter per millimeter Millimeter per pass Millimeter per revolution Millimeter per second Square millimeter per second Cubic millimeter per second Cubic millimeter per second per millimeter Manganese Manganese sulfide Molybdenum MODulator Demodulator Metal oxide semiconductor Molybdenum disulfide M Pa MR MRP ms M/s MS1 MTBF MTS MTTR mV Megapascal Machinability rating Material requirements planning Millisecond Meter per second Medium scale integration Mean time between failure Medium top skive Mean time to repair Millivolt N N NZ NaCl NaC103 NaNOZ NaN03 NaOH NAS Na2S04 NbN NBR NC NCD Nd:YAG NEC neg NEMA NFPA Ni NIOSH NLG1 N“ m N/mm N/mm
N“m/s
NMTBA
No.
Nontrad
NPV
NR
NS
NTS
Newton or Nitrogen
Nit rogen
Sodium chloride
Sodium chlorate
Sodium nitrite
Sodium nitrate
Sodium hydroxide
National Aerospace Standards
Sodium sulphate
Niobium nitride
Nitrile rubber
Numerical control
Normalized cold drawn
Neodymium-doped, yttrium aluminum
garnet
National Electrical Code
negative
National Electrical Manufacturers
Association
National Fire Protection Association
Nickel
National Institute for Occupational Safety
and Health
National Lubricating Grease Institute
Newton meter
Newton per millimeter
Newton per square millimeter
Newton meter per second (Watt)
National Machine Tool Builders Association
Number
Nontraditional
Net present value
Nose radius
Nonstaining
No top skive
o-P
02 Oxygen
OA Overaging
OD Outside diameter
OEM Original equipment manufacturer
OSHA Occupational Safety and Health
Administration
OTM Overtempered martensite
02
P
Pa
PAM
Pans
PAU
Pb
Pc
PCB
pcs/hr
pcs/ shift
PD
PD2
PE
PERA
pH
PID
PM or P/M
pos
PPD
ppm
PROM
PRS
psi
pt
PTC
PVD
PWM
Ounce
Phosphorus or Poise
Pascal
Plasma arc machining
Pascal second
Position analog unit
Lead
Programmable controller
Printed circuit board
Pieces per hour
Pieces per shift
Plastic deformation or Pitch diameter
Plastically deformed debris
Professional engineer
Production Engineering Research
Association
Acidity measure
Proportional, integral derivative
Powder metallurgy
Positive
Pour point depressant
Parts per million
Programmable read only memory
Product relative step
Pound per square inch
Part
Programmed turning center
Physical vapor deposition
Pulse width modulated
R
Ra
RA, B, ., c
RAM
RB
w
RCTL
Ref
R] O
R&O
ROM
rpm
RTL
RUM
s or sec
s
SACD
SAE
s/ cm2
SCR
SE
SES
sfm
SHF
Si
S1
R-S
Resistance
Arithmetic average roughness
Rockwell hardness—A, B, or C scale
Random access memory
Rockwell hardness—B scale
Rockwell hardness—C scale
Resistor capacitor transistor logic
Reference
Reverse osmosis
Rust and oxidation inhibited
Read only memory
Revolution per minute
Resistor transistor logic
Rotary ultrasonic machining
Second
Sulfur
Spheroidized annealed cold drawn
Society of Automotive Engineers
Second per square centimeter
Silicon controlled rectifier
Selective etch
Stationary ElectroStream
Surface feet per minute
Synthetic hydrocarbon fluids
Silicon
International System of Units
s/ in.2 Second per square inch yr Year
Si02 Silicon dioxide
SME Society of Manufacturing Engineers
Sn
ZFM Zero force machining
Tin Zn
S-N
Zinc
Stress vs. number of cycles until failure Zr
Ssl
Zirconium
Small scale integration Zr02
Ssu
Zirconium oxide
Seconds Savbolt Universal
St Stoke –
STEM Shaped Tube Electrolytic Machining
T-U-V
t
Ta
TaC
Ti
TiC
TiN
TI R
TJ
TLV
TMEH
tol
tpi
TPI
TRS
TSCA
TTL
TWA
UAM
Uhp
UNC
UNF
USM
UTM
UTS
v
VBM
Vc
VI
Vll
VO1
VTL
Metric ton
Tantalum
Tantalum carbide
Titanium
Titanium carbide
Titanium nitride
Total indicator runout or Total indicator
reading
Thin joint
Threshold limit valve
Tool and Manufacturing Engineers
Handbook
Tolerance
Threads per inch
Teeth per inch
Transverse rupture strength
Toxic Substances Control Act
Transistor transistor logic
Time weighted average
Ultrasonically assisted machining
Unit horsepower
Unified coarse thread
Unified fine thread
Ultrasonic machining
Untempered martensite
Ultimate tensile strength
Vanadium or Volt
Vertical boring machine
Vanadium carbide
Viscosity index
Viscosity index improver
Volume
Vertical turret lathe
w-Y-z
wW
B,
Wc
We-co
W/cm*
W/in.2
WJ M
W/mm
Watt or Tungsten
Tungsten boride
Tungsten carbide
Tungsten carbide with cobalt binder
Watt per square centimeter
Watt per square inch
Water jet machining
Watt per millimeter
P
/.LA
p fd
p in.
pm
ps
n
7r
$.
Coefficient of friction
Microampere
Micro Farad
Microinch (micron)
Micrometer
Microsecond
Ohm
Pi(3.14159, )
Dollar
Approximately
Plus or minus
Dollar per hour
Dollar
Percent
Perpendicular to
Parallel to
INDEX
A
Abrasion and abrasion resistance
carbide, 3-2 (Fig. 3-1)
cast alloy, 3-2 (Fig. 3-1)
ceramic, 3-2 (Fig. 3-1)
defined, 1-44
high-speed steel, 3-2 (Fig. 3-1)
polycrystalline diamond, 3-2 (Fig. 3-1)
single-crystal diamond, 3-38
tungsten carbide, cemented, 3-26 (Table
contact wheels, rolls, and platens, 11-118
machine tools
3-13)
Abrasive belt machining
backstand, 1 1 – 1 19, 11-12O(Fig.11-116)
centerless, 11-119, 11-120(Fin. 11-116)
free-belt roll, 11-1 19, 11-i20 (Fig
swing-frame, 11-119, 11-120 (Fig.
11-116)
11-116)
vertical,’l1-119, 11-120 (Fig. 11-116)
stock removal rate, 11-118
Abrasive cutoff (see Cutoff, abrasive)
Abrasives (see also Grinding)
advantages, 11-1
applications, I 1-3
honing, I I -I 29
manufactured, 11-15
natural, 11-15
Abrasives, coated
adhesive bonds, 11-42
backings, 11-42
belts, 11-43
cutting fluids, 11-44
discs, f1-43
elements, 11-40 (Fig. 11-15)
flexing, 11-40
grain size, 11-41
joints, 11-44
sheets, 11-43
special forms, 11-44
types, 11-41
Accuracy (see also Tolerance control)
bandsawing, 6-2 (Table 6-l), 6-12
bevel gear blanks, 13-80 (Table 13-31)
boring, 2-2 (Fig. 2-1), 8-78, 8-79 (Table
broaching, 2-2 (Fig. 2-1), 7-2, 7-4 (Table
buffing, 2-2 (Fig. 2-1)
chemical machining, 2-2 (Fig. 2-1)
circular sawing, 6-2 (Table 6-l), 6-36
electrical discharge grinding, 14-62
electrical discharge machining, 2-2 (Fig.
electrical discharge wire cutting, 14-59
Electro-Stream, 14-36
electrochemical discharge grinding, 14-17
electrochemical grinding, 2-2 (Fig. 2-l),
electrochemical honing, 14-22
electrochemical machining, 2-2 (Fig. 2-1),
electrochemical turning, 14-35
electron beam machining, 2-2 (Fig. 2-1),
14-39, 14-40(Fig. 14-40)
electropolishing, 2-2 (Fig. 2-1)
filing, 2-2 (Fig. 2-1)
flame cutting, 2-2 (Fig. 2-1)
gear hobbing, 13-26
gear shaping, 13-26
gears, 13-3
grinding, 2-2 (Fig. 2-1)
gundrills, external chip removal, 9-55
gundrills, internal chip removal, 9-56
hacksawing, 6-2 (Table 6-1), 6-3
hand disk grinding, 2-2 (Fig. 2-1)
8-20)
7-1)
chucks, 8-54
2-1)
14-19
14-32
Accuracy (cont.)
hand grinding, 2-2 (Fig. 2-1)
honing, 2-2 (Fig. 2-1)
jig boring, 8-110
lapping, 2-2 (Fig.2-1)
laser beam drilling, 14-66
laser beam machining, 2-2 (Fig. 2-1)
lathes, toolroom, 8-3, 8-6 (Table 8-2)
milling, 2-2 (Fig. 2-l), 10-7
multiple-spindle automatic bar and chucknumerical control machine tools, 5-10
photochemical machining, 14-90 (Table
plasma arc machining, 2-2 (Fig. 2-1)
polishing, 2-2 (Fig. 2-1)
reamers and reaming, 2-2 (Fig. 2-l), 9-109
(Table 9-36), 9-126 (Table 9-43), 9-132
shaped tube electrolytic machining, 14-36
shaping, 2-2 (Fig. 2-1)
tapped threads, 12-68
thread milling, 12-108
turning, 2-2 (Fig. 2-l), 8-2
twist drilling, 2-2 (Fig. 2-1), 9-2,9-3 (Table
ultrasonic machining, 14-8
Acidity, cutting fluids, 4-29
Acme screw threads, centralizing
ing machines, 15-37
14-30), 14-9I
9-1)
allowances, tolerances, and clearances, 12-
applications, 12-33
basic dimensions, 12-33, 12-38 (Table
diameter-pitch combinations, 12-33, 12-38
thread form and symbols, 12-33(Fig. 12-12)
33 (Fig. 12-11), 12-34(Fig. 12-13)
12-18)
(Table 12-19)
Activators, ECM, 14-25
Active cutting oils, 4-5
Adaptive control
applications, 5-66
classifications, 5-66
concepts, 5-47
dimensional control, 5-67,5-68 (Fig. 5-38)
drilling, 9-4
justification, 5-67
sensor technology, 5-68
surface roughness, 5-68
tool wear, 5-69
trends, 5-66
cutting fluids, 4-5
electrolyte, 14-25
greases, 4-43
lubricants, industrial, 4-38, 4-47
Adhesion, defined, 1-45
Aerobic bacteria, 4-26,4-34
Air deflector nozzle, grinding wheel, I 1-47
Air-line oilers, 4-50, 4-51 (Fig. 4-25) (see also
Air-spray oilers, 4-5 1, 4-52 (Fig. 4-26)
All-loss methods, lubricant application, 4-49
Alloyed tungsten carbide (see Carbide, tungAlternate set, 6-6 (Fig. 6-5)
Alumina (see Aluminum oxide)
Aluminum and alloys
abrasivecutoffwheels, 11-122(Table11-23)
bandsawing, 6-17
broaching constant, 1-22 (Table 7-5)
carbide cutting tools
classifications, 3-22 (Table 3-11)
geometry, 8-30 (Table 8-4)
speeds and feeds, 3-25 (Table 3-12), 3-
titanium grades, 3-27
tungsten grades, 3-21 (Table 3-10)
carbide-tipped boring tools, geometry, 8-
cast cobalt-based alloy cutting tools
Additives
Mist lubrication)
sten, alloyed)
29 (Table 3-16)
86 (Table 8-22)
Aluminum and alloys, cast cobalt-based alloy
cutting tools (cont.)
geometry, 3-15 (Table 3-7)
speeds and feeds, 3-17 (Table 3-8)
ceramic tools, geometry, 3-35 (Table 3-21)
circular sawing, 6-44 (Table 6-9)
counterboring, 9-136,9-I37 (Table 9-47)
cut-and-peel mask etchants, 14-86 (Table
cutting fluids, 4-10 (Table 4-2)
drilling, multiple-lip,externalchip-removal,
high-pressure coolant, 9-97 (Table 9-25)
drilling, twist, 1-20(Fig. 1-36), 9-90 (Table
electron beam machining, 14-38 (Table
end milling, 10-56 (Table 10-8)
expansion, thermal, 8-108 (Table 8-26)
face and back-off angles, HSS broaches,
7-18 (Table 7-4)
grinding discs for, 11-39 (Table 11-15)
grinding fluids, 11-46 (Table 11-16)
grinding wheels for
centerless, 11-26 (Table 11-7)
cylindrical, 11-28 (Table 11-8)
internal, 11-29 (Table 11-9)
surface, 11-25 (Table 11-6)
gundrilling, 9-58 (Table 9-11)
gundrilling, multiple-lip, internal-chipremoval, 9-96 (Table 9-24)
hacksawing, 6-8 (Table 6-2)
high-speed steel tools, geometry, 8-29
(Table 8-3)
laser drilling, 14-67 (Table 14-20)
machinability ratings, 1-49 (Table 1-10)
material removal rate
(Table 6-10)
14-29)
9-20), 9-103
14-14)
circular sawing, 6-44 (Table 6-9), 6-45
electron beam machining, 14-40 (Fig.
14-39)
milling; 10-52 (Table 10-5)
2), 10-54 (Table 10-7), 10-70
(Table 14-28)
milling, 1-20 (Fig. 1-36), 10-35 (Table 10-
photo/silk screen resist etchants, 14-84
planing, 1-20 (Fig. 1-36), 6-46 (Table 7-10)
plasma arc cutting, 14-79 (Table 14-26)
polycrystalline diamond tools, 3-43
reaming, carbide-tipped, 9-1 14(Table 9-39)
reaming, HSS reamers, 9-128(Table 9-44),
screw machining, 15-8 (Table 15-2)
shaping, gear, 13-67 (Table 13-23)
single-crystal diamond tools, application,
3-39
spade drilling,9-85(Table 9-19), 9-87,9-94
(Table 9-23)
tapping, 12-90,12-91(Table 12-45), 12-102
(Table 12-51)
thread chasers, 12-58, 12-59(Table 12-28),
12-63, 12-64 (Table 12-31)
thread rolling, 12-129 (Table 12-63), 12-
130 (Table 12-64), 12-135 (Table 12-66)
threading, single-point carbide, cutting
speed, 12-52 (Table 12-26), 12-53
threadingtools, high-speed steel, geometry,
12-49, 12-50 (Table 12-24)
tooth pitch, HSS circular saws, 6-43 (Fig.
9-131
6-36)
unit power, single-point turning, 8-65
(Table 8-17)
Aluminum oxide (ceramic)
abrasive, applications, 11-15
advantages, 3-34
applications, 3-34
boring tools, 8-84
coated abrasive, 11-41
coatings for carbide
properties, 3-31 (Table 3-17)INDEX
Aluminum oxide (ceramic), coatings for
carbide (cont.)
speeds, cutting, 3-31
comparative performance vs. carbide, 3-35
cutting fluids, 3-38, 4-9
cylindrical grinding of, 11-28 (Table 11-8)
electron beam machining, 14-38(Table 14-
extended tool life equation, exponents, 1-
history, 3-32
hydrodynamic machining, 14-9 (Table
indexable-insert milling cutters, 10-38
limitations, 3-34
speeds and feeds, 3-36, 3-37 (Fig. 3-16)
surface finish effects, 1-24
tool geometry, 3-34 3-35 (Table 3-21)
tool life vs. cutting speed, 3-29 (Fig. 3-13)
troubleshooting, 3-38 (Table 3-22)
turning tools, 8-25
types, 3-32
ultrasonic machining, 14-11 (Table 14-6
and Table 14-7)
Aluminum oxide/zirconium oxide cofusion
abrasive, 11-5
Amborite, 3-45
Anaerobic bacteria, 4-26, 4-34
Angular cuts, 2-22
Angularity, 2-3 (Fig. 2-3)
Annealing (see Heat treatment)
Anodic dissolution theory
ECM mode, 14-25
etching mode, 14-24
polishing mode, 14-25
types of electrodes, 14-24
ANSI standards (see Standards)
Arbors, milling, 10-22
Area of contact, grinding, 11-13, 11-24,-11-45
Armor plate
drilling, twist, 9-103
threading tools, HSS, geometry, 12-49, 12-
50 (Table 12-24)
abrasive cutoff wheels, 11-122(Table 11-23)
drilling, twist, 9-90 (Table 9-20)
hydrodynamic machining, 14-8(Table 14-
ASP (Antisegregation process) (see Cast
cobalt-based alloys)
Austenite, HSS, 3-9
Austenitizing, HSS, 3-8 (Table 3-3) (see also
Heat treatment)
Automatic bar and chucking machines,
multiple-spindle (see Bar and chucking
machines, multiple-spindle automatic)
Automatic lathes, single-spindle (see Lathes,
single-spindle automatic)
Automatic screw machines (see Screw
machines, single-spindle automatic, and
Screw machines, Swiss-type automatic)
Automation
(Table 3-20)
14), 14-39 (Table 14-15)
47 (Table 1-8)
14-4)
Asbestos and asbestos board
3), 14-9 (Table 14-4)
defined, 16-1
gear shaving, 13-92
islands of, 16-16
machine loading/ unloading, 15-4 (Fig. 15-
pick-and-place manipulators, 16-9
robotics, 16-14
time on machine vs. time in shop, 16-1,
4) 16-1
16-2 (Fig. 16-1)
6
Back rake angle (see Rake angle)
Back taper (see Tool geometry)
Bacteria and bacteria control
cutting fluids, 4-26,4-34
Bacteria and bacteria control (cont.)
Bakelite
industrial lubricants, 4-48 (Table 4-16)
drilling, twist, 9-90 (Table 9-20)
HSS tools, geometry, 8-29 (Table 8-3)
reaming, carbide-tipped, 9-114(Table 9-39)
tapping, 12-102 (Table 12-51)
Balancing, grinding wheel, 11-25, 11-31 (Fig.
Ball bearing spindle, 8-80 (Fig. 8-105)
Ballscrew, boring machines, 8-80
Band filing, 6-22
Band machining (see Bandsawing)
Band polishing, 6-22
Bandsawing (see also Saw bands)
accuracy, 6-12
advantages, 6-11
applications, 6-12, 6-14 (Fig. 6-8)
contouring, 6-11
cost and performance, 6-2 (Table 6-1)
cut thickness, 6-12
cutting fluids, 4-10 (Table 4-2), 6-24
kerf, 6-2
limitations, 6-12
machine tools
11-13)
accessories, 6-19
air-powered table, 6-13
aluminum cutoff, 6-17
capacity, 6-1
diamond band, 6-13
drive systems, 6-18
feed systems, 6-18
fixed table, 6-13
flying cutoff, 6-15
friction saws, 6-13
horizontal-type, 6-15, 6-17 (Fig. 6-12)
hydraulically powered table, 6-13
plate saws, 6-15, 6-16 (Fig. 6-10)
post-type, 6-17
CNC, 6-15, 6-18
scissor-type, 6-15,6-16 (Fig. 6-11), 6-17
tilt-frame universal, 6-i7, 6-18 (Fig.
(Fig. 6-13)
6-15)
verlical-type, 6-13
materials, workpiece, 6-1
speeds and feeds, 6-12, 6-23, 6-25 (Table
6-5), 6-35 (Table 6-7)
Bar and chucking machines, multiple-spindle
arrangement of spindles, 15-29,15-30 (Fig.
attachments
automatic
15-19)
automation equipment, 15-36
back finish slide, 15-36
cross-milling/drilling/ slotting, 15-36
high-speed drilling, 15-36
independent endworking, 15-35
pick-off, 15-36
pickup, 15-35
recessing, 15-36 (Fig. 15-31)
thread rolling, 15-35, 15-36
universal threading, 15-35, 15-36 (Fig.
capacity, 15-29
construction, 15-30, 15-31 (Fig. 15-20 and
Fig. 15-21), 15-32 (Fig. 15-22 and Fig.
15-23), 15-33 (Fig. 15-24)
cutting fluids, 15-38
method of chucking, 15-29
method of indexing, 15-29, 15-30
number of spindles, 15-29
planning tooling setups, 15-37, 15-38(Fig.
15-32 and Fig. 15-33)
safety, 15-39, 15-40
speeds and feeds, 15-37
tolerances held, 15-37
tools
15-30)
carbide tooling, 15-35
Bar and chucking machines, multiple-spindle
automatic, tools (cont.)
cross-slide tools and holders, 15-33, 15-
34 (Fig. 15-26, Fig. 15-27, Fig. 15-28,
and Fig. 15-29)
endworking tools and holders, 15-33
(Fig. 15-25)
troubleshooting, 15-39 (Table 15-10)
Bar-stock rolling, 13-29
Bar-turning engine lathe attachment, 8-4
Batch computer processing, 5-47
Bath oiling, 4-53
Bench lathe, 8-3
Beryllium and alloys
abrasive cutoff wheels, 11-122(Table 11-23)
cut-and-peel mask etchants, 14-86 (Table
cutting fluids, 4-10 (Table 4-2)
drilling, laser, 14-67 (Table 14-20)
grinding fluids, 11-46 (Table 11-16)
14-29)
Beta rays, 14-71
Bevel cutting, plasma arc, 14-76 (Fig. 14-74)
Bevel gears (see Gears and gear manufacturing)
Biodegradation
defined, 4-56
disposal method, industrial lubricants, 4-56
Blades, hacksaw
geometry, tooth, 6-6 (Fig. 6-4)
materials, 6-5
pitch, tooth, 6-6
set, tooth, 6-6 (Fig. 6-5)
size, 6-6
tension, 6-5
Blanking dies, 14-44
Blind-hole broach, 7-30 (Fig. 7-33)
Block tooling, boring (see Boring bars and
Block-type boring bars, 8-89
Blotters, grinding wheel, 11-23
Blunt start, defined, 12-2, 12-3 (Fig. 12-1)
Boiling point
Boring t001s)
copper, 14-49 (Table 14-17)
graphite, 14-49 (Table 14-17)
iron, 14-49 (Table 14-17)
tungsten, 14-49 (Table 14-17)
Boring bars, 15-45 (Fig. 15-40), 15-46 (Fig.
15-42and Fig. 15-43), 15-47(Fig. 15-44and
Fig. 15-45), 15-51 (Fig. 15-53).
Boring heads, 15-47,15-48 (Fig. 15-46and Fig.
15-47), 15-49 (Fig. 15-48 and Fig. 15-49)
Boring, jig
applications, 8-101
cutting fluids, 8-109
cutting tools, 8-106
in-process measurements, 8-109
machine tools
accessories, 8-103
adjustable rail, 8-102,8-103 (Fig. 8-145)
fixed-bridge, 8-102, 8-103 (Fig. 8-146)
maintenance, 8-109
measuring systems, 8-103
NC/CNC, 8-102, 8-103 (Fig. 8-147)
openside, 8-102 (Fig. 8-144)
operating parameters, 8-108
temperature control, 8-108 (Table 8-26)
workholding, 8-104
bar support, 15-51 (Fig. 15-53 and Fig.
boring bars, 15-45(Fig. 15-40), 15-46(Fig.
15-42 and Fig. 15-43), 15-47 (Fig. 15-44
and Fig. 15-45)
boring fixtures, 15-51
boring heads, 15-47, 15-48 (Fig. 15-46and
Fig. 15-47), 15-49 (Fig. 15-48 and Fig.
boring tools, 15-49, 15-50(Fig. f 5-50, Fig.
15-51and Fig. 15-52)
Boring machines, horizontal (HBM’s)
15-54)
15-49)
1-2INDEX
Boring machines, horizontal (HBM’s) (cont.)
combined operations, 15-52 (Fig. 15-55
controls
and Fig. 15-56)
CNC, 15-44
MDI, 15-44
floor-type, 15-43, 15-44 (Fig. 15-39)
planer-type, 15-43 (Fig. 15-38)
portable, 15-43
table-type, 15-43(Fig. 15-37)
traveling-bar, 15-44
traveling-head, 15-44
Boring machines, vertical (VBM’s)
applications, 15-61 (Fig. 1s-70)
automatic toolchanging, 15-59, 15-60(Fig.
capacities, 15-55, 15-56 (Table 15-12), 15-
57 (Table 15-13)
controls, 15-55
construction, 15-54
defined, 15-53, 15-54(Fig. 15-57)
machine loading, 15-57, 15-58(Fig. 15-62)
tooling, 15-58 (Fig. 15-63), 15-59 (Fig. 15-
64, Fig. 15-65 and Fig. 15-66)
workholding, 15-60 (Fig. 15-68)
Boring, precision (see also Boring tools)
accuracy, 2-2 (Fig. 2-l), 8-78, 8-79 (Table
applications, 8-100
combining operations, 8-91, 8-95 (Fig.
cutting fluids
drills, indexable-insert, 9-48, 9-49 (Fig.
engine lathe attachment, 8-10, 8-11 (Fig.
jig boring, 8-101
machine tools
15-67)
8-20)
8-127)
nozzle orientation, 4-15
types, 4-10 (Table 4-2)
9-38)
8-14)
center-drive, 8-81 (Fig. 8-108)
dial-type, 8-82, 8-83 (Fig. 8-1 11)
double-end, 8-81 (Fig. 8-107)
horiLonta1 single-end, 8-80 (Fig. 8-106)
NC, 8-82, 8-83 (Fig. 8-112), 8-84 (Fig.
vertical, 8-81, 8-82 (Fig. 8-109)
way-type, 8-81, 8-82 (Fig. 8-110)
8-113)
safety, 18-13
slide operation, 8-78
spindle types, 8-80
surface finish, 1-24, 1-25 (Fig. 1-40)
toolholders, 8-87
troubleshooting, 8-89, 8-100 (Table 8-25)
workholding, 8-95
adjustable heads, 8-88, 8-89 (Fig. 8-119)
block reamers, 9-119,9-120 (Fig. 9-121)
block tooling, 15-46 (Fig. 15-42 and Fig.
block-type bars, 8-89
carbide
tools, 8-82
Boring tools (see also Boring, precision)
15-43), 15-47 (Fig. 15-44)
geometry, 8-84, 8-85 (Table 8-21, Fig.
8-114, and Fig. 8-115)
grades, 3-22 (Table 3-11)
cartridges, 8-89, 8-90 (Fig. 8-122), 8-92
cast cobalt-based alloys, speeds and feeds,
chatter minimization, 8-89, 8-100 (Table
coated carbide
(Table 8-24)
3-17 (Table 3-8)
8-25)
performance vs. uncoated carbide, 3-33
speeds and feeds, 3-30, 3-33 (Table
(Table 3-18)
3-18)
Boring tools (cont.)
cubic boron nitride
geometry, 3-47
performance vs. grinding, 3-47 (Table
speeds and feeds, 3-46 (Table 3-24), 3-
3-25)
47 (Table 3-25)
fixed toolholders, 8-94, 8-95 (Fig. 8-128)
fixtures, 15-51
generating-type heads, 8-91
geometry, 15-50(Fig. 15-50,Fig. 15-51and
Fig. 15-52)
gunbores, 9-121,9-122 (Fig. 9-124)
heads, 15-48 (Fig. 15-46 and Fig. 15-47),
15-49 (Fig. 15-48 and Fig. 15-49)
HSS, powdered metal grades, 3-13
indexable inserts
retention of, 18-12
types, 8-87
materials, 8-83, 15-49
multiple-tool bars, 8-88, 8-89 (Fig. 8-117
and Fig. 8-118)
polycrystalline diamond
geometry, 3-44 (Table 3-23)
performance vs. carbide and singlecrystal diamond, 3-44 (Table 3-23)
speeds and feeds, 3-44 (Table 3-23)
preset tools, 8-99
qualified tools, 8-99
retractable boring tools, 8-91, 8-94 (Fig.
8-124)
setup, 8-99
single-crystal diamond, geometry, 3-39,3-
single-tool bars, 8-88 (Fig. 8-116)
size control, automatic, 8-91, 8-94 (Fig.
solid and tipped tools, 8-84, 8-86 (Table
abrasive for ultrasonic machining, 14-6
cylindrical grinding of, 11-28 (Table 11-8)
hardness, 14-6
internal grinding of, 11-29 (Table 11-9)
ultrasonic machining of, 14-11(Table 14-6)
41 (Fig. 3-19)
8-125)
8-22)
Boron carbide (Norbide)
Boron nitride (see Cubic boron nitride)
Borozon cutting tools, 3-45
Bottle oiler, 4-49, 4-50 (Fig, 4-21)
Boundary lubrication, 4-36, 4-37 (Fig. 4-17)
Box milling, 10-6 (Fig. 10-7)
Brass
abrasivecutoffwheels, 11-122(Table12-23)
bandsawing, 6-25 (Table 6-5)
broaching constant, 7-22 (Table 7-5)
carbide cutting tools
classifications, 3-22 (Table 3-11)
geometry, 8-30 (Table 8-4)
speeds and feeds, 3-25 (Table 3-12), 3-
tungsten grades, 3-21 (Table 3-10)
cast cobalt-based alloy cutting tools
geometry, 3-15 (Table 3-7)
speeds and feeds, 3-17 (Table 3-8)
ceramic tools, geometries, 3-35(Table3-21)
circular sawing, 6-44 (Table 6-9)
counterboring, 9-136, 9-137 (Table 9-47)
cutting fluids, staining, 4-9
drilling,
29 (Table 3-16)
multiple-lip, external-chip-removal,
high-pressure coolant, 9-97 (Table
spade, 9-87, 9-94 (Table 9-23)
twist, 1-20 (Fig. 1-36)
9-25)
electrodes, EDM, 14-51
electron beam machining, 14-39 (Table
end milling, 10-56 (Table 10-8)
grinding discs for, 11-39 (Table 11-15)
14-15)
Brass (cont.)
grinding wheels
for centerless grinding, 11-26 (Table
for cylindrical grinding, 11-28 (Table
for internalgrinding, 11-29(Table 11-9)
for surface grinding, 11-25(Table 11-6)
gundrilling, multiple-lip, internal-chipremoval, 9-96 (Table 9-24)
hacksawing, 6-8 (Table 6-2)
HSS tools, geometry, 8-29 (Table 8-3)
machinability ratings, 1-49 (Table 1-10)
material removal rate
circular sawing, 6-44 (Table 6-9)
milling, 10-52 (Table 10-5)
11-7)
11-8)
milling, 1-20 (Fig. 1-36), 10-35 (Table 10-
planing, 1-20 (Fig. 1-36), 7-46 (Table 7-10)
polycrystalline diamond tools, 3-43
reaming, carbide-tipped, 9-114(Table9-39)
reaming, HSS reamers, 9-128 (Table 9-44),
screw machining, 15-8 (Table 15-2)
shaping, gear, 13-67 (Table 13-23)
tapping, 12-102 (Table 12-51)
thread chasing, 12-63, 12-64(Table 12-31)
thread rolling, 12-129 (Table 12-63), 12-
130 (Table 12-64), 12-135 (Table 12-66)
threading tools, single-point carbide, cutting speed, 12-52 (Table 12-26), 12-53
tool-life exponents, 1-46 (Table 1-6)
tooth pitch, HSS circular saw blades, 6-43
(Fig. 6-36)
unit power, single-point turning, 8-65
(Table 8-17)
2), 10-54 (Table 10-7)
9-131
Brazing, tipped tools, 8-70
Brick
abrasive cutoff wheels, 11-122(Table 11-23)
hydrodynamic machining, 14-9 (Table
Broaches (see also Broaching)
blind-hole, 7-30 (Fig. 7-33)
carbide
application, 7-23
grades, 3-22 (Table 3-1I )
14-4)
construction, 7-23
contour, 7-27
cut-and-recut, 7-32
design, 7-25 (Table 7-7)
double-cut, 7-30
dovetail, 7-26
follower ends, 7-24
force, cutting, 7-22
gears, 13-33
grinding of, 11-96
handling, 7-36
high-speed steel
applications, 7-23
grades, 3-10
grinding wheels for sharpening, 11-30
(Table 11-10)
high-speed steel, powdered metal
keyway, 7-26 (Fig. 7-23), 7-30, 7-3
material, 7-23 (Table 7-6)
nomenclature, 7-12 (Fig. 7-9 and
pilots, 7-24
pot, 7-28 (Fig. 7-27 and Fig. 7-28),
pripciples, 7-1, 7-2 (Fig. 7-1)
progressive (nibbling-type), 7-26
pull ends, 7-24
repair, 7-36
rotary, 7-28, 7-29 (Fig. 7-29), 7-32
rotary-cut, 7-30 (Fig. 7-32)
application, 7-23
grades, 3-13
7-34)
7-2)
(Fig.
Table
4-60
1-3INDEX
Broaches (conl.)
round-hole, 7-29 (Fig. 7-30)
sharpening, 7-35,7-36 (Fig. 7-38)
slab, 7-26
spline, 7-26,7-3 1 (Fig. 7-35), 13-33
straddle, 7-27 (Fig. 7-25 and Fig. 7-26)
strength, 7-20
tooth geometry
slot, 7-26
chip space, 7-15 (Fig. 7-12)
cut per tooth, 7-14 (Fig. 7-11),7-16
design data, 7-16 (Table 7-3)
pitch, 7-14 .
troubleshooting, 7-36 (Fig. 7-39), 7-37
(Table 7-8)
V-shaped, 7-26
wobble, 14-60
Broaching (see also Broaches)
accuracy, 2-2 (Fig. 2-I )
advantages, 7-1
applications, 7-1, 7-2 (Fig. 7-2 and 7-3),
broach strength, 7-20
broaching constant, 7-22 (Table 7-5)
construction, broach, 7-23
cutting fluids
7-34
fluid flow recommendations, 4-14
selection, 4-10 (Table 4-2), 7-35
electrochemical, 14-28 (Fig. 14-29)
force, cutting, 7-22
gears and splines, 13-33
high-speed, 7-33
internal broaches, 7-29
knurls, 7-29
limitations, 7-3
machine tools
(Table 4-3)
classification, 7-6, 7-7 (Fig. 7-5)
dual-ram, vertical, 7-8 (Fig. 7-6)
horizontal continuous, 7-10 (Fig. 7-7)
horizontal internal, 7-9
horizontal one-way, 7-10
horizontal two-way, 7-10
portable, 7-11
pot broaches, 7-11 (Fig. 7-8)
pulldown internal, 7-9
pullup internal, 7-9
pushdown internal, 7-9
rotary, 7-11
selection, 7-7
single-ram, vertical, 7-8
special, 7-1 1
universal, 7-9
CNC, 7-7
materials, broach, 7-23
nomenclature, 7-12 (Fig. 7-9 and Table
principles, 7-1, 7-2 (Fig. 7-1)
serrations, 7-29
sharpening, broach, 7-35, 7-36 (Fig. 7-38)
speeds and feeds, 7-3
strip, 7-30 (Fig. 7-31)
surface broaches, 7-26
threads, 7-29
tooth geometry, 7-13
troubleshooting, 7-36 (Fig. 7-39), 7-37
workholding, 7-32
workpiece materials, 7-3,7-4 (Table 7-1)
abrasive cutoff wheels, 11-122(Table 11-23)
bandsawing, 6-25 (Table 6-5)
broaching constant, 7-22 (Table 7-5)
carbide cutting tools
classifications, 3-22 (Table 3-11)
geometry, 8-30 (Table 8-4)
speeds and feeds, 3-25 (Table 3-12), 3-
7-2)
(Table 7-8)
Bronze
29 (Table 3-16)
Bronze (cont.)
tungsten grades, 3-21 (Table 3-10)
cast-cobalt-based alloy cutting tools
geometry, 3-15 (Table 3-7)
speeds and feeds, 3-17 (Table 3-8)
ceramictools, geometries, 3-35 (Table3-21)
circular sawing, 6-44 (Table 6-9)
cutting fluids, staining, 4-9
drilling, 1-20 (Fig. 1-36)
end milling, 10-56 (Table 10-8)
expansion, thermal, 8-108 (Table 8-26)
grinding discs for, 11-39 (Table 12-15)
grinding wheels
for centerless grinding, I 1-26 (Table
for cylindrical grinding, 11-28 (Table
for internalgrinding, 1 1-29(Table 11-9)
for surface grinding, 11-25(Table 11-6)
gundrilling, 9-58 (Table 9-11)
gundrilling, multiple-lip, internal-chipremoval, 9-96 (Table 9-24)
hacksawing, 6-8 (Table 6-2)
HSS tools, geometry, 8-29 (Table 8-3)
machinability ratings, 1-49 (Table 1-10)
material removal rate
circular sawing, 6-44 (Table 6-9)
milling, 10-52 (Table 10-5)
11-7)
11-8)
milling, 1-20 (Fig. 1-36), 10-35 (Table IOphoto/silk screen resist etchants, 14-84
planing, 1-20(Fig. 1-36), 7-46 (Table 7-10)
polycrystalline diamond tools, 3-43
reamers, HSS reamers, 9-128 (Table 9-44)
reaming, carbide-tipped, 9-114(Table 9-39)
sawing, 6-2
shaping, gear, 13-67 (Table 13-23)
spade drilling, 9-87,9-94 (Table 9-23)
tapping, 12-102(Table 12-51)
thread chasing, 12-63, 12-64(Table 12-31)
thread rolling, 12-129 (Table 12-63), 12-
tooth pitch, HSS circular saw blades, 6-43
unit power, single-point turning, 8-65
2), 10-54 (Table 10-7)
(Table 14-28)
130 (Table 12-64)
(Fig. 6-36)
(Table 8-17)
Buffer storage, 5-39
Buffing, 2-2 (Fig. 2-1)
Built-up edge
broaching tools, 7-3, 7-6 (Fig. 7-4)
defined, 1-4 (Fig. 1-7), 1-5, 1-6 (Fig. 1-13)
high-speed steel vs. carbide tools, 1-28
milling, 1-32 (Fig. 1-44), 10-72
steel machining, 1-23
surface roughness effects, 1-4 (Fig. 1-8)
titanium carbide tools, 3-27
turning tools, 1-4, 8-76
Bump attachment, 12-134 (Fig. 12-102)
Burnishing button, 7-12 (Table 7-2)
Bushings
drilling, 9-75
reaming, 9-126
BZN compacts, 3-45
C
Cam generation
jig boring, 8-108 (Fig. 8-159)
milling, 10-2
Cam operation
boring machines, 8-80
multiple-spindle automatic bar and chucking machines, 15-22
single-spindle automatic screw machines,
15-7 (Fig. 15-7)
Swiss-type automatic screw machines, 15-
24 (Fig. 15-15)
Cam operation (cont.)
CAMI-grade coated abrasives, 11-41
Cap screw recesses, 9-137 (Table 9-48)
Carbide, boron (see Boron carbide)
Carbide, coated
advantages, 3-30
applications, 3-32
cutting fluids, 3-32
drills, 9- 16
extended tool life equation, exponents, 1-
47 (Table 1-8)
history, 3-30
indexable-insert milling cutters, 10-37
limitations, 3-30
multilayer coatings, 3-31
properties of coatings, 3-30
speeds and feeds, 3-32
surface finish effects, 1-24
types of coatings, 3-30
uncoated carbides, compared with, 3-33
Carbide, micrograin, 3-20
Carbide size and distribution
3-4), 3-12 (Fig. 3-5)
(Fig. 3-41, 3- 12 (Fig. 3-5)
Carbide, titanium, cemented
(Table 3-18)
high-speed steel, conventional, 3-1 1 (Fig,
high-speed steel, powdered metal, 3-11
additives for ceramic inserts, 3-32
advantages, 3-26
applications, 3-27
ceramics, compared with, 3-35 (Table3-20)
coatings for carbide, 3-30
cutting fluids, 3-30, 4-9
drills, 9-16
extended tool life equation, exponents, 1-
grinding wheels and grinding
47 (Table 1-8)
centerless, 11-26 (Table 11-7)
cylindrical, 11-28 (Table 11-8)
general, 3-24
internal, 11-29 (Table 11-9)
history, 3-25
indexable-insert milling cutters, 10-37
operating parameters, 3-29
properties and grades, 3-26 (Table 3-14)
sharpening safety, 18-13
surface finish effects, 1-23
thread grinding, 12-125 (Table 12-60)
tool geometry, 3-29
tungsten carbide, compared with, 3-26, 3-
turning, 8-25
Carbide, tungsten, alloyed
columbium carbide, 3-20
electrodes, EDM, 14-52
hafnium carbide, 3-20
manufacturing of, 3-19
niobium carbide, 3-20
tantalum grades, 3-19
thread grinding, 12-125 (Table 12-60)
titanium grades, 3-I9
Carbide, tungsten, cemented
advantages, 3-18
alloyed grades, 3-19
application, 3-20
boring tools, 8-86 (Table 8-22)
broaches, 7-23
classifications, 3-20
compared with titanium carbide, 3-26, 3-
cutting fluids, 3-30, 4-9
drills, 9-16
drills, small-hole, 9-67
expansion, thermal, 8-108 (Table 8-26)
hobs, 13-39
28 (Table 3-15 and Fig. 3-12)
hobs, 13-39
28 (Table 3-15 and Fig. 3-12)
1-4INDEX
Carbide, tungsten, cemented (cont.)
extended tool life equation, exponents, 1-
47 (Table 1-8)
grinding wheels
for centerless grinding, 11-26 (Table
for cylindrical grinding, 11-28 (Table
for general grinding, 3-24
for internal grinding, 11-29(Table 1I-9)
11-7)
Il-8)
history, 3-16
manufacture of, 3-16
micrograin, 3-20
milling cutter inserts, 10-37
operating parameters, 3-24, 3-25 (Table
planing tools, 7-44 (Table 7-9)
selection, 3-20, 3-24 (Fig. 3-10)
shaping tools for chromium alloys, 7-51
sharpening safety, 18-13
straight grades, 3-18
substrate for polycrystalline diamond
surface finish effects, 1-24
taps, 12-86
thread grinding, 12-125(Table 12-60)
troubleshooting, 3-26 (Table 3-13)
turning tools, 8-25
ultrasonic machining of, 14-11 (Table 14-6
and Table 14-7)
Carbon (see also Graphite)
3-12)
(Fig. 7-62)
tools, 3-42
abrasive cutoff wheels, 1 1-122(Table11-23)
ceramic tools, geometries for, 3-35 (Table
grinding discs, 11-39 (Table 11-15)
grinding wheels, centerless, 11-26 (Table
machinability effects on steels, 1-58
polycrystalline diamond, 3-43
twist drilling, 9-90 (Table 9-20)
ultrasonic machining of, 14-11 (Table 14-7)
carbide cutting tools, classification, 3-22
hydrodynamic machining, 14-8 (Table
laser beam cutting, 14-72(Table 14-23)
3-21)
11-7)
.
Cardboard
(Table 3-1I )
14-3)
Cartridge filters, 4-23
Cartridges, boring bar, 8-89,8-90 (Fig. 8-122),
8-92 (Table 8-24)
Cast cobalt-based-alloys
advantages, 3-14
applications, 3-15
boring tools, 8-83
chemical composition, 3-14 (Table 3-6)
cutting fluids for, 3-16
drills, 9-16
grinding, abusive, 1-33, 1-35 (Fig. 1-50)
grinding wheels for, 11-30 (Table 11-10}
history, 3-14
operating parameters, 3-16
tool geometry, 3-15 (Table 3-7)
tool grinding, 3-16
turning tools, 8-25
abrasivecutoff wheels, 11-122(Table 11-23)
broaching constant, 7-22 (Table 7-5)
carbide cutting tools
geometry, 8-30 (Table 8-4)
speeds and feeds, 3-29 (Table 3-16)
carbide-tipped boring tools, 8-86 (Table
cast cobalt-based alloy cutting tools
ceramic cutting tools
hobs, 13-39
Cast iron
8-22)
geometry, 3-I5 (Table 3-7)
speeds and feeds, 3-17 (Table 3-8)
Cast iron, ceramic cutting tools (cont.)
speeds and feeds, 3-38 (Fig. 3-17)
tool geometries, 3-35 (Table 3-21)
circular sawing, 6-44 (Table 6-9)
coated vs. uncoated carbides, performance,
counterboring, 9-136, 9-137 (Table 9-47)
cubic boron nitride, speeds and feeds, 3-46
cutting fluids, 4-10 (Table 4-2)
drilling
3-33 (Table 3-18)
(Table 3-24), 3-47 (Table 3-25)
indexable-insert, 9-82 (Table 9-18)
multiple-lip, external-chip-removal,
high-pressure coolant, 9-97 (Table
spade, 9-94 (Table 9-23)
twist, 1-20(Fig. 1-36),9-90 (Table 9-20)
end milling, 10-56 (Table 10-8)
grinding discs for, 11-39 (Table 11-15)
grinding fluids, 11-46 (Table 11-16)
grinding wheels
9-25)
for centerless grinding, 11-26 (Table
for cylindrical grinding, 11-28 (Table
for internal grinding, 1 1-29(Table 11-9)
gundrilling, multiple-lip, internal-chipremoval, 9-96 (Table 9-24)
hobbing, 13-55(Table 13-20)
honingfluids, 11-126,ll-127 (Table 11-24)
machinability ratings, 1-49 (Table 1-10)
material removal rate
circular sawing, 6-44 (Table 6-9)
electron beam machining, 14-40 (Fig.
milling, 10-52(Table 10-5)
milling, 1-20 (Fig. 1-36), 10-54 (Table 10-
planing, 1-20 (Fig. 1-36), 7-46 (Table
reaming, carbide-tipped, 9-1 14(Table9-39)
reaming, HSS reamers, 9-128 (Table 9-44)
shaping, gear, 13-67 (Table 13-23)
shaping tools for, 7-50 (Fig. 7-60)
tensile strength, 6-44 (Table 6-9)
thread chasing, 12-63, 12-64(Table 12-31)
thread grinding, 12-125 (Table 12-60)
thread milling, 12-114 (Table 12-56)
threading tools, high-speed steel, geometry,
12-49, 12-50 (Table 12-24;)
threading tools, single-point carbide, cutting speed, 12-52(Table 12-26), 12-53
titanium carbide vs. tungsten carbide cutting tools, 3-28 (Table 3-15)
tool life exponents, 1-46 (Table 1-6)
unit power, single-point turning, 8-65
(Table 8-17)
Cast iron, chilled
11-7)
11-8)
14-39)
7), 10-69
7-10)
carbide tools, speeds and feeds, 3-29 (Table
cubic boron nitride tools, speeds and feeds,
grinding wheels, surface, 11-25(Table 11-6)
milling, 10-35(Table 10-2)
broaching constant, 7-22 (Table 7-5)
carbide-tipped boring tools, 8-86 (Table
chasers, rake angle, 12-58, 12-59 (Table
drilling,
indexable carbide insert, 9-87, 9-92
spade, 9-85 (Table 9-19)
twist, 9-90 (Table 9-20)
3-16)
3-46 (Table 3-24)
Cast iron, ductile
8-22)
12-28)
(Table 9-22)
face and back-off angles,’ HSS broaches,
7-18 (Table 7-4)
Cast iron, ductile (cont.)
grinding wheels
for centerless grinding, 11-26 (Table
for cylindrical grinding, 11-28 (Table
for internal grinding 11-29(Table 11-9)
for surface grinding 11-25(Table 11-6)
11-7)
11-8)
gundrilling, 9-58 (Table 9-11)
machinability ratings, 1-49 (Table 1-10)
planing, 7-46 (Table 7-10)
shaping tools, 7-50 (Fig. 7-60)
tapping, 12-90,12-91 (Table 12-45), 12-102
threading tools, high-speed steel, geometry,
broaching constant, 7-22 (Table 7-5)
carbide cutting tools
classifications, 3-22 (Table 3-11)
speeds and feeds, 3-25 (Table 3-12)
tungsten grades, 3-21 (Table 3-10)
carbide-tipped boring tools, geometry, 8-
cast cobalt-based alloys
(Table 12-51)
12-49, 12-50(Table 12-24)
Cast iron, gray
86 (Table 8-22)
speeds and feeds, 3-38 (Fig. 3-17)
tool geometries, 3-15 (Table 3-7)
carbide inserts, compared with, 3-35
tool geometries, 3-35 (Table 3-21)
chasers, rake angle, 12-58, 12-59 (Table
cutting fluids, 4-10 (Table 4-2)
face and back-off angles, HSS broaches,
grinding discs, 11-39 (Table 11-15)
grinding wheels
ceramics
(Table 3-20)
12-28)
7-18 (Table 7-4)
for centerless grinding, 11-26 (Table
for cylindrical grinding 11-28 (Table
for internal grinding 11-29(Table 11-9)
for surface grinding 11-25(Table 11-6)
high-speed steel tools, geometry, 8-29
machinability ratings, 1-49 (Table 1-10)
milling, 10-35 (Table 10-2)
sawing, 6-2
shaping, tools for, 7-50 (Fig. 7-60)
speeds and feeds
gundt-illing, 9-58 (Table 9-11)
hacksawing, 6-8 (Table 6-2)
planing, 7-46 (Table 7-10)
11-7)
11-8)
(Table 8-3)
tapping, 12-90,12-91 (Table 12-45), 12-102
threading tool, high-speed steel, geometry,
tooth pitch, HSS circular saw blades, 6-43
(Table 12-51)
12-49, 12-50 (Table 12-24)
(Fig. 6-36)
Cast iron, malleable
broaching constant, 7-22 (Table 7-5)
carbide cutting tools
classifications, 3-22 (Table 3-11)
speeds and feeds, 3-25 (Table 3-12), 3-
29 (Table 3-16)
titanium grades. 3-27
titanium-vs. tungsten grades, 3-28
tungsten grades, 3-21 (Table 3-10)
carbide-tipped boring tools, 8-86 (Table
(Table 3-15)
8-22)
cast cobalt-based alloy cutting tools
geometry, 3-15 (Table 3-7)
speeds and feeds, 3-17 (Table 3-8)
circular sawing, 6-44 (Table 6-9)
cubic boron nitride tools, speeds and feeds,
3-46 (Table 3-24)
1-5INDEX
Cast iron, malleable (cont.)
cutting fluids, 4-10 (Table 4-2)
drilling
indexable carbide insert, 9-87, 9-92
(Table 9-22)
multiple-lip, external-chip-removal,
high-pressure coolant, 9-97 (Table
twist, 1-20(Fig. 1-36),9-90 (Table 9-20)
face and back-off angles, HSS broaches,
7-18 (Table 7-4)
grinding discs for, 11-39 (Table 11-15)
gundrilling, multiple-lip, internal-chipremoval, 9-96 (Table 9-24)
hacksawing, 6-8 (Table 6-2)
machinability ratings, 1-49 (Table 1-10)
material removal rate
circular sawing, 6-44 (Table 6-9)
milling, 10-52 (Table 10-5)
9-25)
milling, 1-20 (Fig. 1-36), 10-35 (Table 10-
planing, 1-20 (Fig. 1-36), 7-46 (Table 7-10)
reaming, HSS reamers, 9-128 (Table 9-44)
sawing, 6-2
shaping, tools for, 7-50 (Fig. 7-60)
tapping, 12-90,12-91 (Table 12-45), 12-102
thread chasing, 12-63, 12-64 (Table 12-31)
threadingtools, high-speed steel, geometry,
unit power, single-point turning, 8-65
Cast iron, nodular
carbide tools
2), 10-54 (Table 10-7)
(Table 12-51)
12-49, 12-50 (Table 12-24)
(Table 8-17)
speeds and feeds, 3-25 (Table 3-12), 3-
tungsten grades, 3-21 (Table 3-10)
tungsten grades vs. titanium grades, 3-
cast cobalt-based alloy tools
geometry, 3-15 (Table 3-7)
speeds and feeds, 3-17 (Table 3-8)
chasers, rake angle, 12-58, 12-59 (Table
cubic boron nitride tools, speeds and feeds,
drilling, indexable carbide insert, 9-87, 9-
machinability ratings, 1-49 (Table 1-10}
milling, 10-35 (Table 10-2)
sawing, 6-2
29 (Table 3-16)
28 (Table 3-15)
12-28)
3-46 (Table 3-24)
92 (Table 9-22)
Cast steel (see Steel, cast)
Cathode, electrochemical machining, 14-33
Cathode ray tube, 5-48
CBN (see Cubic boron nitride)
Center drilling, 15-40
Center drilling and facing machines
milling and centering, 15-41 (Fig. 15-35),
15-42
plunge facing and centering, 15-40, 15-41
(Fig. 15-34)
Center drills. 9-19. 9-35
Center holes; 11-90
Center-column machines, 15-78 (Fig. 15-99)
Center-drive boring machine, 8-81(Fig. 8-108)
Center-type workholding
grinding, 11-87
turning
face drivers, 8-48 (Fig. 8-66)
mandrels, 8-48, 8-49 (Fig. 8-67, Fig.
steadyrests and follower rests, 8-49, 8-
types, 8-47, 8-48 (Fig. 8-64)
Centerless grinding (see Grinding, centerless
Centers (see Center-type workholding)
Centrifuges
8-68, and Fig. 8-69)
50 (Fig. 8-70)
cylindrical)
Centrifuges (cont.)
cutting fluids, 4-18 (Fig. 4-4)
electrolytes, 14-27
grinding fluids, 11-48
abrasive cutoff wheels, 11-122 (Table 11-23)
carbide tools, classifications, 3-22 (Table
cutting fluids, 4-10 (Table 4-2), 4-13
grinding discs, 11-39 (Table 11-15)
laser drilling, 14-68 (Table 14-21)
polycrystalline diamond tools, 3-43
Ceramic (tile)
3-11)
Ceramic cutting tools (see Aluminum oxide)
Chain oiling, 4-53
Chamfering (see also Chamfering tools)
tap sharpening, 12-103 (Fig. 12-58)
thread chaser sharpening, 12-64
Chamfering tools, polycrystalline diamond
geometry, 3-44 (Table 3-23)
performance vs. carbide, 3-44 (Table 3-23)
speeds and feeds, 3-44 (Table 3-23)
Chasing, thread (see Thread chasing and
Chatter
(see also Chamfering)
thread chasers)
boring tools, 8-100
ceramic tools, 3-38 (Table 3-22)
drilling, 9-102
grinding, 11-109
milling, 10-74
reaming, 9-131 (Fig. 9-137)
safety consideration, 18-14
turning tools, 8-76
Chemical composition
cast cobalt-based alloys, 3-14 (Table 3-6)
high-speed steel, 3-6 (Table 3-1), 3-7
high-speed steel, powdered metal, 3-13
machinability effects, 1-58
(Table 3-4 and Table 3-5)
Chemical cutting fluids, 4-6
Chemical etching (see Etchants and etching,
Chemical machining
chemical)
accuracy, 2-2 (Fig. 2-1)
chemical milling, 14-83
cut-and-peel maskants, 14-82
ECM operations, 14-32
etchants
etching rate, 14-82
selection, 14-82
special, 14-82
fundamentals, 14-81
photochemical machining, 14-89
photographic resists, 14-82
screen resists, 14-82
surface integrity
depth of alterations, 1-30 (Table 1-4)
types of alterations, 1-28 (Table 1-3)
Chemical milling
applications, 14-83
cleaning, 14-83
etchants, 14-86(Table 14-29)
fillet radii, 14-89
grain direction, 14-89
masking, 14-83
processing, 14-89
stock removal, 14-89
surface finish, 14-89
tapers, 14-89
Chemical resistance, coatings for carbide
Chemical tool wear, defined, 1-45
Chemical vapor deposition (CVD), 3-30
Chip breakers (see Chip control and chip
Chip color, 1-8
Chip control and chip breakers
inserts, 3-31 (Table 3-17)
breakers)
Chip control and chip breakers (cont.)
broaches, 7-17, 7-18 (Fig. 7-13 and Fig.
chip color, 1-8
chip thickness vs. power, milling, 10-50
drills, 9-36, 9-39 (Fig. 9-22)
fundamentals, 1-7
indexable inserts, 8-32, 8-38 (Fig. 8-50),
single-point tools
7-14)
8-39
defined, 1-5, 1-6 (Fig. 1-13), 8-30 (Fig,
ground, 8-31 (Table 8-5 and Table 8-6)
mechanical, 8-31 (Fig. 8-43)
orthogonal cutting model, 1-1
undeformed chip thickness, defined, 8-
undeformed chip thickness vs. horseChip curlers (see Chip control and chip
Chip formation, theory of
8-42)
66 (Fig. 8-96)
power, 8-64
breakers)
chip breakers, 1-5, 1-6 (Fig. 1-13)
chip color, 1-8
chip length ratio, 1-2 (Fig. 1-1)
continuous chips with BUE, 1-4 (Fig. 1-7)
cutting ratio, 1-2 (Fig. 1-1)
discontinuous chips, 1-3 (Fig. 1-6)
extensive shear, 1-4, 1-5 (Fig. 1-11)
inclination angle, 1-6, 1-7 (Fig. 1-15 and
Fig. 1-16)
milling, 10-3
orthogonal cutting model, 1-1
safety considerations, 18-11
secondary shear, 1-4, 1-5 (Fig. 1-10)
shear strain and strain rate, 1-3 (Fig. 1-4)
single-point turning, 1-3
symbols, 1 – 1 .
Stabler’s Rule, 1-6
Chip length ratio (see Cutting ratio)
Chip processing, 4-18, 4-19 (Fig. 4-5), 4-20
Chip welding, milling cutters, 10-72
Chip wringer (see Chip processing)
Chipping (see also Cracking)
ceramics, 3-38 (Table 3-22)
milling cutter inserts, 10-72
tungsten carbide, cemented, 3-26
turning tools, 8-76
(Fig. 4-6)
Chucking fixture, 8-60, 8-63 (Fig. 8-94 and
Fig. 8-95)
Chucking machines, automatic, multiplespindle (see Bar and chucking machines,
multiple-spindle)
Chucking machines, automatic, multiplespindle vertical
application, 15-62, 15-63 (Fig. 15-72)
attachments, 15-62
defined, 15-62(Fig. 15-71)
tooling, 15-62
Chucks (see also Vises)
diaphragm, 8-60
grinding, 11-87
indexing, 8-60
jaw-type
jaw force requirements, 8-54 (Fig. 8-80)
independent, 8-54 (Fig. 8-81)
installation, operation, and safety, 8-60
lever-type power, 8-56, 8-57 (Fig. 8-85
master jaws, 8-57, 8-60 (Fig. 8-87)
selection, 8-53
self-centering, 8-55 (Fig. 8-82)
special top jaws, 8-57, 8-61 (Fig. 8-89)
standard top jaws, 8-57, 8-58 (Table
8-15), 8-59 (Table 8-16), 8-61 (Fig.
wedge-type power, 8-55 (Fig. 8-83), 8-
and Fig. 8-86)
8-88)
56 (Fig. 8-84)
1-6INDEX
Chucks (cont.)
magnetic
demagnetizers, 11-60
maintenance, 11-60
types, 11-60
milling attachments, 10-23
spring-jaw, 8-60
trunnion-type, 8-60
vacuum, 11-60
drilling, 9-36
drilling, small-hole, 9-89
hydrodynamic machining, 14-7 (Table 14-
2), 14-9 (Table 14-4)
Circular interpolation, 5-39
Circular sawing (see also Saw blades)
Circuit board
accuracy, 6-36
advantages, 6-36
cost and performance, 6-2 (Table 6-1)
cutting fluids, 4-10 (Table 4-2), 6-45
engine lathe attachment, 8-9, 8-10 (Fig.
fixturing, 6-40, 6-41 (Fig. 6-31)
kerf, 6-2
limitations, 6-36
machine tools
8-11)
CNC, 6-37, 6-38 (Fig. 6-26)
horizontal-travel, 6-39 (Fig. 6-28)
miter-cut, 6-40
plate saws, 6-39 (Fig. 6-29), 6-40 (Fig.
radial bench-type, 6-40
table-type, pivot arm, 6-37 (Fig. 6-23)
vertical pivot arm, 6-37 (Fig. 6-24)
vertical-column, 6-39 (Fig. 6-27)
6-30)
materials, workpiece, 6-1
operating costs, 6-36
safety, 6-46
sawblades, 6-40
speeds and feeds, 6-44 (Table 6-9), 6-45
tooling costs, 6-36
tooth geometry, 6-42 (Fig. 6-33, Fig. 6-34,
and Fig. 6-35)
tooth pitch, 6-43 (Fig. 6-36), 6-44
troubleshooting, 6-43 (Table 6-8)
Circulation systems,industrial lubricants,4-51
Clamping (see Workholding)
Clamping fixture, 11-61, 11-62(Fig. 11-36and
Clamping, inserts, ceramic, 3-36 (Fig. 3-15)
Clarification and clarity (see also Filtration
Fig. 11-37)
and filters)
cutting fluid
defined, 4-15, 4-17
measurement, 4-16
methods, 4-17
electrolyte, 14-27
Clay (see Thickeners, grease)
Clearance angle
boring tools, 8-85
broaches, 7-13 (Fig. 7-10), 7-14 (Fig. 7-11)
cast cobalt-based alloys, 3-15 (Tuble 3-7)
cutoff tools, 8-46 (Fig. 8-61)
defined, 8-27
hacksaw blades, 6-6 (Fig. 6-4)
saw bands, 6-19 (Fig. 6-16), 6-20 (Fig. 6-17)
saw blades, 6-42 (Fig. 6-33)
single-crystal diamond, 3-40
shaping tools, 7-50 (Fig. 7-60 and Fig. 7-
CNC (see Numerical control and computer
Coating
Cobalt-based alloys, cast (see Cast cobaltCoefficient of expansion (see Expansion,
61), 7-51 (Fig. 7-62)
numerical control)
for carbide, 3-31 (Table 3-17)
for high-speed steel, 3-10
based alloys)
coefficient of)
Coefficient of friction (see Friction, coefficient
Cold isostatic pressing (see Isostatic pressing,
cold)
Collar oiling, 4-53
Collets
of)
air actuation, 8-52
draw-in, 8-51 (Fig. 8-74)
stock pullback, 8-52
stock pushback, 8-52
expanding collets, 8-52, 8-53 (Fig. 8-78)
push-out, 8-51 (Fig. 8-73)
stationary, 8-50, 8-51 (Fig. 8-71 and Fig.
step chucks, 8-52, 8-53 (Fig. 8-77)
tap holders, 12-97 (Fig. 12-53 and Fig.
8-72)
12-54)
Columbium
cylindrical grinding wheels for, 11-28
tapping, 12-90, 12-91 (Table 12-45)
cemented tungsten carbide, 3-18
single-crystal diamond, 3-41
(Table 11-8)
Columbium carbide, 3-20
Compacting
Compax, 3-42
Composite ceramics composition, 3-32 (see
Composites
also Aluminum oxide)
drilling, twist, 9-106
hydrodynamic machining, 14-7 (Table
laser cutting, 14-72(Table 14-23)
14-2)
Compounded cutting oils, 4-5
Compressive strength (see Strength, compresComputer fire protection
causes of fire, 18-16
first aid equipment, 18-17
types of protection, 18-16
sive)
Computer, host, 5-27
Computer, mainframe, 5-47
Computers, mini and micro, 5-47
Concentricity broaching, 7-32
Concentricity, hole
boring, 8-79 (Table 8-20)
calculations, 2-3 (Fig. 2-3), 2-53
Concrete, abrasive cutoff wheels for, 11-122
Conductivity, electrical
(Table 11-23)
copper, 14-49 (Table 14-17)
graphite, 14-49 (Table 14-17)
iron, 14-49 (Table 14-17))
tungsten, 14-49 (Table 14-17)
copper, 14-49 (Table 14-17)
graphite, 14-49 (Table 14-17)
iron, 14-49 (Table 14-17)
single-crystal diamond, 3-38
titanium carbide, 3-26
tungsten, 14-49 (Table 14-1 7)
Conductivity, thermal
Conformal and nonconformal surfaces, 4-35
Continuous chip, 1-2 (Fig. 1-2)
Continuous path controls, 5-31
Continuous wave lasers (see Lasers and laser
beam machining)
Contour broach, 7-27
Contouring
bandsawing, 6-13
jig grinding, 11-100, 11-101 (Fig. 11-106),
milling, 10-70
NC concepts, 5-35
planing, 7-47
(Fig. 4-13)
11-102 (Fig. 11-108)
Controls (see Machine controls)
Coolant (see Cutting fluid and Grinding fluid)
Coolant-fed twist drills, 9-45
Copper and alloys (see also Brass and Bronze)
Copper and alloys (cont.)
abrasivecutoffwheels, 11-122(Table 11-23)
bandsawing, 6-25 (Table 6-5)
boiling point, 14-49 (Table 14-17)
carbide cutting tools
classifications, 3-22 (Table 3-1I)
geometry, 8-30 (Table 8-4)
tungsten grades, 3-21 (Table 3-10)
speeds and feeds, 3-25 (Table 3-12), 3-
carbide-tipped boring tools, 8-86 (Table
cast cobalt-based alloy cutting tools, speeds
ceramics,tool geometries, 3-35(Table3-21)
circular sawing, 6-44 (Table 6-9)
cutting fluids, staining, 4-9
drilling
29 (Table 3-16)
8-22)
and feeds, 3-17 (Table 3-8)
multiple-lip, external-chip-removal,
high-pressure coolant 9-97 (Table
spade, 9-94 (Table 9-23)
twist, 1-20 (Fig. 1-36), 9-90 (Table 9-
elasticity, modulus of, 14-49(Table 14-17)
electrical conductivity, 14-49(Table 14-17)
electrodes, EDM, 14-44, 14-51
end milling, 10-56 (Table 10-8)
face and back-off angles, HSS broaches,
7-18 (Table 7-4)
forces and power when machined with
single-crystal diamond tools, 1-19 (Fig.
grinding discs for, 11-39 (Table 11-15)
grinding fluids, 11-46 (Table 11-16)
grinding wheels for cylindrical grinding,
hacksawing, 6-8 (Table 6-2)
heat to vaporize, 14-49 (Table 14-17)
HSS tools, geometry, 8-29 (Table 8-3)
laser drilling, 14-67 (Table 14-20)
machinability ratings, 1-49 (Table 1-10)
material removal rate, circular sawing, 6-
melting point, 14-49 (Table 14-17)
milling, 1-20(Fig. 1-36), 10-35(Table 10-2)
photo/silk screen resist etchants, 14-84
planing, 1-20 (Fig. 1-36)
reaming, carbide-tipped, 9-114(Table9-39)
strength, tensile, 14-49 (Table 14-17)
tapping, 12-90,12-91 (Table 12-45), 12-102
thermal conductivity, 14-49 (Table 14-17)
thread chasers, 12-58, 12-59(Table 12-28),
thread rolling, 12-130 (Table 11-64)
threading tools, HSS, geometry, 12-49,12-
tool life exponents, 1-46 (Table 1-6)
tooth pitch, HSS circular saws, 6-43 (Fig.
9-25)
20), 9-103
1-35)
11-28 (Table 11-8)
44 (Table 6-9)
(Table 14-28)
(Table 12-51)
12-63, 12-64 (Table 12-31)
50 (Table 12-24)
6-36)
unit power, single-point turning, 8-65
(Table 8-17)
Copper graphite EDM electrodes, 14-51
Copper tungsten EDM electrodes, 14-51
Core drilling
drills, 9-17, 9-36 (Table 9-7)
rotary ultrasonic, 14-11
Corrosion and corrosion protection
cutting fluids
cast iron, 4-13
protection mechanism, 4-4
tests, 4-29
water quality effects, 4-24
grease, 4-46
inhibitors
electrolytes for ECM, 14-25
1-7INDEX
Corrosion and corrosion protection (cont.)
industrial lubricants, 4-47 (Table4-15),
4-48
Cost estimating, NC, 5-11
Counterboring and counterbores
carbide-tipped, 9-136
defined, 9-134
deep-hole, 9-135
disposable-insert, 9-134
indexable-insert, 9-134,9-135 (Fig. 9-142)
inserted-blade, 9-134, 9-135 (Fig. 9-141)
interchangeable, 9-134, 9-135 (Fig. 9-140)
interchangeable pilot, 9-134
multidiameter, 9-136, 9-138 (Fig. 9-145)
recesses for cap screws,9-136,9-137 (Table
recesses for machine screws, 9-136, 9-138
solid, 9-134,9-135 (Fig. 9-139)
speeds and feeds, 9-136
Countersinking and countersinks
chatterless, 9-139, 9-142 (Fig. 9-151)
cutting fluids, 4-10 (Table 4-2)
defined, 9-134
disposable insert, 9-141 (Fig. 9-149)
machine-type, 9-139, 9-140 (Fig. 9-148)
rivet sizes, 9-142 (Table 9-51)
ship plate, 9-139 (Table 9-50)
9-48)
(Table 9-49)
CPM (Crucible Particle Metallurgy) (see Cast
Cracking (see also Chipping)
cobalt-based alloys)
brazing of tipped tools, 8-70
ceramics, 3-38 (Table 3-22)
micro and macro in machining, 1-30(Table
milling, 10-72
titanium carbide, 3-26
tungsten carbide, cemented, 3-26
turning tools, 8-76
Crane and parking attachments, 10-22
Crankshaft milling
defined, 10-3
machine tools, 10-20 (Fig. 10-33)
Crater resistance (see also Cratering)
carbide, 3-2 (Fig. 3-1)
cast alloy, 3-2 (Fig. 3-1)
ceramic, 3-2 (Fig. 3-1)
hafnium vs. titanium carbide, coated
carbide inserts, 3-31
high-speed steel, 3-2 (Fig. 3-1)
polycrystalline diamond, 3-2 (Fig. 3-1)
Cratering (see also Crater resistance)
defined, 3-1, 8-76
milling cutters, 10-72
turning tools, 8-76
tungsten carbide, 3-26 (Table 3-13)
Crown grinding, 11-71
Crown shaving, 13-91
CRT (see Cathode ray tube)
Crush-form wheel dressing
general, 11-32, 11-33 (Table 11-11)
thread grinding, 12-121
applications, 11-16
coated abrasive, 11-41
gear grinding, 13-94
hardness, 14-6
hob sharpening, 13-62
honing, I I-129
advantages, 3-45
applications, 3-45, 3-47
boring tools, 8-84
ceramics, compared with, 3-46
cutting fluid, 3-47
defined, 3-45
diamond tools, compared with, 3-45
speeds and feeds, 3-46 (Table 3-24)
I-4), 1-33
Cubic boron nitride (CBN) abrasive
Cubic boron nitride (CBN) cutting tools
CBN cutting tools (cont.)
tool geometry, 3-47
turning tools, 8-25
types, 3-45
Cut-and-recut broach, 7-32
Cutoff (see Hacksawing, Bandsawing, Circular
Cutoff, abrasive
sawing, and Cutoff, abrasive)
grinding fluid selection, 11-46 (Table 11-
machine tools, 11-124(Fig. 11-118)
principles, 11-121
troubleshooting, 11-124(Fig. 11-117)
wheels, 11-121
Cutoff tools, screw machining, 15-18 (Table
Cutting angle, 8-28
Cutting fluid (see also Grinding fluid)
Id), 11-121
15-7), 15-19
accessibility to the cut, 4-3
application, 4-13
chip removal, 4-5
concentration control, 4-27
cooling properties, 4-4
corrosion protection, 4-4, 4-13,4-24
drilling, 9-89
economic evaluation, 4-8 (Table 4-1)
filtration, 4-15, 4-20
fluid flow recommendations, 4-14 (Table
forces and power, effects on, 1-19
friction, metalcutting, 4-1
health and safety, 4-32, 18-13
history, 4-1
jig boring, 8-109
lubricating properties, 4-4
machinine tool design considerations, 4-16
metallurgical compatibility, 4-9
milling, 10-60
multiple-spindle automatic bar and chucking machines, 15-38
performance evaluation, 4-30, 4-31 (Fig.
rancidity control, 4-26
recycling and disposal, 4-53
Rehbinder effect, 4-3
reservoir cleaning, 4-27 (Table 4-6)
selection, 4-7
shaving, gear, 13-91
storage of concentrate. 4-23
4-3)

4-12)
Swiss-type automatic screw machines,
15-27
testing
microbiological properties, 4-34
physical properties, 4-28
threading, single-point, 12-54
tool material compatibility, 4-9
types, 4-5, 4-9
water quality, 4-23
water treatment, 4-25
Cutting friction (see Friction, metalcutting)
Cutting model, orthogonal (see Orthogonal
Cutting oil, 4-5
Cutting rate (see Material removal rate)
Cutting ratio, defined, 1-2(Fig. 1-l),4-2 (Fig.
Cutting tool material
cast cobalt-based alloys, 3-14
ceramic, 3-32
coated carbide, 3-30
cubic boron nitride, 3-45
diamond, polycrystalline, 3-41
diamond, single-crystal, 3-38
vs. forces and power, 1-19
high-speed steel, 3-4
high-speed tool steel, powdered metal,
history, 3-3, 3-4 (Fig. 3-3)
properties of, 3-1
cutting model)
4-1)
3-11
Cutting tool material (cont.)
selection of, 3-1
surface finish, affects upon, 1-23
tantalum carbide, 3-19
titanium carbide, 3-25
tool steel, carbon and low-alloy, 3-4
tungsten carbide, cemented, 3-16
CVD (see Chemical vapor deposition)
Cyclonic separators (see Hydrocyclones)
Cylindrical grinding (see Grinding, cyclinCylindrical-die thread rolling, 12-132
Cylindricity, 2-3 (Fig. 2-3)
drical)
D
Deburring, attachment for screw machines,
Decarburization
15-2I
carbide substrates, 3-31
high-speed steel, 3-9
Deformation, plastic (see Plastic deformation)
Deformation zones, metalcutting, 4-2
Deionization, water, 4-26 (Table4-5)(see also
Distillation, water, and Softening, water)
Demagnetizer, 11-60
Denim, hydrodynamic machining, 14-9(Table
Density
ceramic insert, cold-pressed, 3-34 (Table
composite ceramics, hot-pressed, 3-34
lubricants, industrial, 4-39
titanium carbide, 3-26 (Table 3-14)
electrochemical discharge grinding, 14-16
electrochemical grinding, 14-19
Depth of cut
defined, 8-2
threading, 12-53
Dermatitis, cutting fluids, 4-33
Diagnostics, 5-23
Dial-type (rotary-index)machines, 15-78(Fig.
Diamond abrasive
14-4)
3-19)
(Table 3-19)
Density, current
15-98)
applications, 11-15
coated abrasives, 11-41
hardness, 14-6
ultrasonic machining, 11-41
Diamond bandsawing, 6-13, 6-22
Diamond cutting tools (see Single-crystal
diamond and Polycrystalline diamond cutting tools)
Diamond dressing
general, 11-27, 11-32 (Fig. 11-14)
thread grinding, 12-120 (Fig. 12-82)
Diamond knots, 14-65
Die heads
fully receding, 12-55(Fig. 12-25)
self-opening, 12-55
carbide, 14-45
electrical discharge machining, 14-44
electrical discharge wire cutting, 14-59
milling methods, 10-3
application, 14-45
cooling, 14-48
for electrical discharge grinding, 14-62
for electrical discharge machining, 14-45
for electrical discharge wire cutting, 14-60,
filtering, 14-48
requirements, 14-45
types, 14-47
blanking, 14-44
spline rolling, 13-27
Die manufacturing
Dielectric fluid
14-61
Dies
1-8INDEX
Dies (ront.)
threading
applications, 12-108
rolling, 12-131
types, 12-107, 12-108 (Fig. 12-63, Fig.
12-64, and Fig. 12-65)
Diffusion, defined, 1-45
Direct numerical control (DNC)
applications, 5-29
concepts, 5-29
future developments, 5-30
history, 5-29
interface, 5-33
operating guidelines, 5-30
abrasive, 11-35
dressing and trueing, 11-39
grain ske, 11-35
selection, 11-39 (Table 11-15)
speeds, operating, I 1-39
structure, 1 1-35
Dish, 1-26 (Fig. 1-41)
Disposal
cutting fluids, 4-55
lubricants, industrial, 4-55
VS.CNC, 5-23
Discs, abrasive
Distillation, watcr, 4-26 (Table 4-5) (see also
Softening, water, and Deionization, water)
Distortion in machining, 1-36, 1-37 (Fig. 1-56
and Fig. 1-57)
Distributed numerical control (see Direct
numerical control)
Dividing heads, 10-24 (Fig. 10-37)
DNC (see Direct numerical control)
Dog, lathe, 8-48
Dogbone inserts, 12-51
Double-cut planer, 7-39
Double-end machines, 15-77
Double-housing planer, 7-38 (Fig. 7-40)
Dovetail, broach, 7-26
Dovetail form tool, 8-41
Down milling
advantages, 10-4 (Fig. 10-2 and Fig. 10-3)
defined, 10-3, 10-4 (Fig. 10-1)
involute splines, 13-22 (Table 13-1I )
symbols, 2-3 (Fig. 2-3)
Dressing, grinding wheel
abrasive sticks, 11-29
abrasive wheels, 11-29
defined, I 1-27
electrical discharge grinding, 14-62 (Fig.
jig grinding wheels, 11-98, 11-99 (Fig. I l –
104), 11-100 (Fig. 11-105)
metal cutters, 11-29
rotary diamond wheels, 11-29
single-point diamonds, 11-29
thread grinding wheels, 12-120
gundrills, 9-56
multispindle, 9-8, 9-9 (Fig. 9-8)
portable, 9-12
accuracy, 2-2 (Fig. 2-1), 9-2,9-3 (Table 9-1)
applications, 9-102, 15-8 (Table 15-2)
attachments
Drawings, engineering
14-60)
Drill heads
Drilling (see also Drills)
high-speed, 15-36
screw machine, 15-25
center, 15-18, 15-40
cuttability tests, 1-43
cutting fluids
coolant-fed twist drills, 9-89
fluid flow recommendations, 4-14
high-pressure coolant drills, 9-93, 9-98
indexable-insert drills, 9-89
nozzle size and orientation, 4-15
(Table 4-3), 9-89
(Fig. 9-101)
Drilling, cutting fluid (cont.)
selection, 4-10 (Table 4-2)
spade drills, 9-92
Electro-Stream, 14-36
electromechanical, 14-15
electron beam machining, 14-38 (Table
engine lathe attachment, 8-10
errors in hole geometry, 9-2,9-3 (Fig. 9-1)
feed rate effects, 9-2
laser beam, 14-66 (Fig. 14-65)
machine tools
14-14)
deep-hole, 9-9, 9-10 (Fig. 9-11), 9-11
gang, 9-6, 9-7 (Fig. 9-5)
general considerations, 9-1
light-duty, sensitive, 9-4, 9-5 (Fig. 9-2)
multispindle, 9-8 (Fig. 9-7)
portable, 9-12
radial, 9-7 (Fig. 9-6)
small-hole, 9-11, 9- 12 (Fig. 9-13)
Swiss-type automatic screw machines,
trepanning, 9-11
turret, 9-9 (Fig. 9-Y), 9-10 (Fig. 9-10)
upright (vertical), 9-5 (Fig. 9-3), 9-6
(Fig. 9-12)
15-27
(Fig. 9-4)
miniature hole, 9-106
power, indexable-insert drills, 9-80, 9-82
power, twist drills, 9-78
principles, 9-1
rotary ultrasonic, 14-10, 14-12(Table 14-8
screw machining, 15-18
shaped-tube electrolytic machining, 14-35
specific power consumption, 1-19, 1-20
speeds and feeds
(Tuble 9-18), 9-84 (Fig. 9-95)
and Fig. 14-10)
(Fig. 1-36)
coolant-fed twist drills, 9-87
core drills, 9-87
definitions, 9-84
indexable-insert drills, 9-87,9-92 (Table
multidiameter drills, 9-87
multiple-lip, external-chip-removal,
high-pressure coolant drills, 9-97
(Table 9-25)
multiple-lip, internal-chip-removal
gundrills, 9-96 (Table 9-24)
small-hole drills, 9-89
spade drills, 9-87, 9-94 (Table 9-23)
trepanning tools, internal chip removal,
twist drills, 9-84, 9-90 (Table 9-20)
twist drills, deep-hole, 9-87,9-92 (Table
9-22)
9-99 (Table 9-26)
9-21)
starting holes, 9-102
surface alterations, 1-30 (Table 1-4)
surface finish, 9-4
surface integrity
AISI 4340 steel, 1-29, 1-32 (Fig. 1-45)
depth of surface alterations, 1-30(Table
maraging steel, 18% nickel, 1-29, 1-33
types of alterations, 1-28 (Table 1-3)
indexable-insert drills, 9-80, 9-84 (Fig.
spade drills, 9-80
twist drills, 9-44 (Fig. 9-31), 9-79
quick-change tooling, 9-68, 9-69 (Fig.
9-74 and Fig. 9-75)
straight-shank, 9-67
taper-shank drills, 9-67
1-4)
(Fig. 1-46)
thrust force
9-96)
toolholders
torque, twist drills, 9-44 (Fig. 9-3I ) , 9-79
troubleshooting
Drilling, troubleshooting (cont.)
gundrilling, 9-106 (Table 9-34)
indexable-insert drills, 9-105 (Table
twist drilling, 9-104 (Table 9-32)
9-33)
ultrasonic, 14-15
workholding, 9-69
workpiece material effects, 9-2
workpiece materials, 9-102
Drills (see also Drilling, Gundrills and gundril!ing, and Core drilling and drills)
abrasive cutoff wheels for, 11-122 (Table
cast cobalt-based alloys, 3-15
combination drill and reamer, 9- 1 I3 (Fig.
cutting action, 9-1
drill grinders, 9-97, 11-94 (Fig. 11-94 and
flat, 9-48 (Fig. 9-36)
gund rills
11-23)
9-113)
Fig. 11-95)
external-chip-removal, 9-54,9-55 (Fig.
internal-chip-removal, 9-56, 9-61 (Fig.
speeds and feeds, 9-58 (Table9-11)9-89
half-round, 9-48 (Fig. 9-37)
high-speed steel
grades, 3-10
grinding wheels, centerless, 11-26
grinding wheels, cylindrical, 11-28
grinding wheels, toolroom, 11-30
high-speed steel, powdered metal, grades,
indexable-insert
advantages, 9-48, 9-49 (Fig. 9-38)
applications, 9-51
insert geometry, 9-50 (Fig. 9-40)
insert grades, 9-50
insert holders, 9-50
limitations, 9-49
power 9-80, 9-82 (Table 9-18)
setup, 9-106
size range, 9-50
speeds and feeds, 9-87
tool designs, 9-50 (Fig. 9-39)
9-49)
9-56, Fig. 9-57 and Fig. 9-58)
(Table 11-7)
(Table 11-8)
(Table 11-10)
3-13
multiple-lip, pressure-coolant, 9-57, 9-63
(Fig. 9-60)
reconditioning
high-pressure coolant, 9-101, 9-103
spade drill blades, 9-99, 9-102 (Table
twist, 9-96
selection, 9-2
small-hole, 9-66, 9-67 (Fig. 9-71), 9-89
spade
(Fig. 9-108)
9-31)
advantages, 9-51
applications, 9-51
blades, 9-51 (Fig. 9-41), 9-52 (Fig. 9-42
holders, 9-53 (Fig. 9-45), 9-54 (Fig. 9-
limitations, 9-51
speeds and feeds, 9-87
and Fig. 9-43), 9-53 (Fig. 9-44)
46, Fig. 9-47, and Fig. 9-48)
straight-flute, 9-48
trepanning tools, 9-62,9-64 (Fig. 9-64 and
Fig. 9-65), 9-89
twist, coolant-fed
advantages, 9-45
coolant supply, 9-47 (Fig. 9-35)
limitations, 9-47
speeds and feeds, 9-87
types, 9-47
accuracy, 9-3 (Table 9-1)
twist, solidINDEX
Drilling, twist, solid (colzt.)
aircraft, 9-38
automotive series, 9-38
center drills, 9-19, 9-35
chipbreaker, 9-36, 9-39 (Fig. 9-22)
circuit-board, 9-36
classifications, 9-14, 9-I6
core drills, 9-17, 9-36 (Table 9-7),9-87
cotter-pin, 9-38
crankshaft, 9-38
dimensional tolerances, 9-17, 9-18
double-margin, 9-36, 9-39 (Fig. 9-21)
drill points, 9-41
helix angle, 9-45 (Fig, 9-33)
high-helix, 9-17
left-hand, 9-36
lip relief, 9-43 (Table 9-8)
low-helix, 9-17
materials, 9-15
multidiameter, 9-17, 9-38 (Fig. 9-17
and Fig. 9-18),9-40 (Fig. 9-24),9-87
nomenclature, 9-14
pipe-flange, 9-38
for plastics, 9-38
for portable drilling units, 9-40
rail, 9-38
Rotabroach, 9-40 (Fig. 9-23)
sizes, 9-16
specials, 9-40 (Fig. 9-24)
speeds and feeds, 9-84, 9-90 (Table
spotting, 9-35
straight-shank, 9-17, 9-28 (Table 9-6),
surface treatments, 9-15
taper-shank, 9-17,9-21 (Table 9-4),9-
web thickness, 9-43 (Table 9-9)
web thinning, 9-44 (Fig. 9-30 and Fig.
(Table 9-2),9-20 (Table 9-3)
9-20)
9-40 (Fig. 9-24)
27 (Table 9-5),9-40 (Fig. 9-24)
9-32)
wear, twist, 9-93, 9-100 (Table 9-27)
Driver plate (see Face drivers, turning)
Drop feed cup, 4-49 (Fig. 4-19 and Fig. 4-20)
Dropping point, grease, 4-46
Dual-ram broaching machines, 7-8 (Fig. 7-6)
Dynamic viscosity (see Viscosity)
Dynamometers
cross sensitivity, 1-15
design considerations, 1-15
dial indicator, 1-16 (Fig. 1-28)
differential transformer, 1-16 (Fig. 1-30)
hydraulic pressure, 1-I6 (Fig. 1-29)
hysteresis, 1-15
magnetic straingage, 1-16, 1-17(Fig. 1-31)
optical, 1-16
piezoelectric crystal, 1-17
pneumatic, 1-16
rigidity and sensitivity, 1-15
wire resistance strain gage, 1-16, 1-17(Fig.
1-32 and Fig. 1-33)
E
Earplugs (see Noise control)
EBM (see Electron beam machining)
ECDG (see Grinding, electrochemical disECG (see Grinding, electrochemical)
ECH (see Honing, electrochemical)
ECM (see Electrochemical machining)
Economic evaluation
computer-assisted NC programming, 5-53
(Table 5-18)
cutting and grinding fluids, 4-8 (Table 4-1)
electrochemical machining, 14-34
hobbing, 13-60
machining, 1-59
NC equipment, 5-13
charge)
Economic evaluation (cont.)
programmable controllers, 5-4
ECT (see Electrochemical turning)
EDG (see Grinding, electrical discharge)
Edge chamfer (see Tool geometry)
Edge wear (see also Tool life and tool wear)
polycrystalline diamond tools, 3-43
triple-layer coated carbide tools, 3-3I
EDM (see Electrical discharge machining)
EDWC (see Electrical discharge wire cutting)
Efficiency, electrical, ECM, 14-32
Efficiency, mechanical
Elasticity, modulus of
lathes, 8-67
milling machines, 10-53 (Table 10-6)
cemented carbides, 3-18
copper, 14-49 (Table 14-17)
graphite, 14-49 (Table 14-17)
iron, 14-49 (Table 14-17)
tungsten, 14-49 (Table 14-17)
Elastohydrodynamic lubrication, 4-36 (Fig,4-
Electrical conductivity (see Conductivity,
Electrical discharge machining (EDM)
15), 4-37 (Fig. 4-16)
electrical)
accuracy, 2-2 (Fig. 2-1)
applications, 14-44
current and voltage, 14-48 (Fig. 14-48and
Fig. 14-49), 14-49 (Fig. 14-50)
dielectric fluids, 14-45, 14-54 (Fig. 14-52)
electrical discharge grinding, 14-61
electrical discharge wire cutting, 14-59
electrode machining, 14-52
electrode materials, 14-49 (Table 14-17),
electrode orbiting, 14-55
electrode rotating, 14-55
electrode wear, 14-50
glossary of terms, 14-42
machine tools, 14-42 (Fig. 14-41), 14-54
(Fig. 14-52)
material removal rate, 14-50
no-wear, 14-56
polarity, 14-49
power supplies, 14-52 (Fig. 14-51), 14-53
(Table 14-18)
principles, 14-42, 14-43 (Fig. 14-42)
spark gap and overcut, 14-50
surface characteristics, 1-28 (Table 1-3),1-
30 (Table 1-4),1-34 (Fig. 1-49), 14-50
surface integrity
cracks, 1-33, 1-34 (Fig. 1-49), 14-50
depth of alterations, 1-30 (Table 1-4)
Inconel 718 alloy, 1-36 (Fig. 1-53)
types of alterations, 1-28 (Table 1-3),
Waspaloy, 1-32, 1-34 (Fig. 1-48)
14-51
14-50
Electrical discharge wire cutting (EDWC)
accuracy, 14-60
applications, 14-59
dielectric fluids, 14-60
electrode wire, 14-60
machine tools, 14-60, 14-61 (Fig. 14-58)
material removal rate, 14-60
overcut, 14-60
power, 14-60
principles, 14-59(Fig. 14-56and Fig. 14-57)
surface finish, 14-60
surface integrity, 14-60
applications, 14-36
machine tools, 14-36
operating parameters, 14-36
principles, 14-36
Electro-Stream (ES)
Electrochemical discharge grinding (see
Electrochemical honing (see Honing, electroGrinding, electrochemical discharge)
chemical)
Electrochemical machining (ECM) (see also
Electrochemical turning)
anodic dissolution theory, 14-24
applications, 14-28, 14-30 (Fig. 14-34)
cathode design, 14-33
electrolyte flow, 14-34 (Fig. 14-35), 2-2
(Fig. 2-l), 14-32
electrolytes, 14-25
gap control, 14-30
machinability, 14-26, 14-27 (Fig. 14-26)
machine tools, 14-33
principles, 14-24 (Fig. 14-25)
surface integrity
depth of alteration, 1-30 (Table 1-4)
Inconel 718 alloy, 1-36 (Fig. 1-54)
intergranular attack, 1-29, 1-33 (Fig.
types of alterations, 1-28 (Table 1-3)
1-47)
Electrochemical turning (ECT)
applications, 14-35
machine tools, 14-35
operating parameters, 14-35
principles, 14-35 (Fig. 14-36)
applications, 14-51
machining of, 14-52
materials, 14-51
no-wear EDM, 14-57
orbiting, 14-55
physical properties, 14-49 (Table 14-17)
rotating, 14-55
wear, 14-50
wire cutting, 14-60
additives, 14-25
Electro-Stream, 14-36
electrochemical discharge grinding, 14-17
electrochemical grinding, 14-18
electrochemical honing, 14-22
electrochemical machining, 14-34
filtering, 14-27
handling, 14-27
selection, 14-26
shaped tube electrolytic machining, 14-36
special agents, 14-26
types, 14-25, 14-26 (Table 14-12)
Electromechanical drilling, 14-16
Electromechanical machining (EMM)
applications, 14-16
principles, 14-15
Electromechanical turning, 14-16
Electron beam machining (EBM)
accuracy, 2-2 (Fig. 2-1), 14-39, 14-40 (Fig.
beam control, 14-40
beam generation, 14-39
drilling, 14-38 (Table 14-14)
vs. laser beam machining, 14-65
machine tools, 14-41
milling, 14-38operating parameters, 14-39
perforation, 14-38
principles, 14-37 (Fig. 14-37)
slotting, 14-38, 14-39 (Table 14-15)
workholding, 14-41
Electropolishing, 2-2 (Fig. 2-1)
EMD (see Electromechanical drilling)
Emery coated abrasive, 11-41
EMM (see Electromechanical machining)
EMT (see Electromechanical turning)
Emulsifiers and demulsifiers, 4-48 (Table 4-
Emulsions
Electrodes, EDM
Electrolyte
14-40)
16), 4-49
cutting fluids, 4-6
hydraulic fluids, 4-57 (Table 4-17),4-58
invert, 4-58
End cutting edge angle
cast cobalt-based alloys, 3-15 (Table 3-7)
ceramic, 3-35 (Table 3-21)
defined, 8-27
1-10INDEX
End cutting edge angle (cont.)
single-point tools, 8-29 (Table 8-3)
planing tools, 7-44 (Table 7-9)
End form tool, 8-41 (Table 8-11)
End milling (see Milling)
End mills (see Milling cutters)
End relief angle (see Relief angle)
Engine lathe, 8-3
Engler system, viscosity measurement, 4-38
Entering angle, 8-28
Equations
boring
end relief angle, 8-87 (Table 8-22)
radial rake angle, 8-87 (Table 8-22)
surface finish, theoretical, 1-24, 1-25
cross-sectional area, minimum, 7-21
cut per tooth, maximum, 7-16
pitch, short broaches, 7-15
pulling force, maximum, 7-20
pulling force, minimum, 7-22
pushing force, maximum, 7-21
pushing force, minimum, 7-21
wheelhead angle, broach sharpening,
(Fig. 1-40)
broaching
7-35
drilling, spade, thrust, 9-80
drilling, twist
drill speed vs. spindle speed, 9-84
power, 9-79
thrust, 9-79
torque, 9-79
dynamometers
frequency, undamped natural, 1-15
gage factor, wire resistance strain gage,
total charge, piezoelectric crystal, 1-17
voltage across capacitor, 1-17
equivalent diameter
application, 11-24
defined, 11-13
gears and splines
basic dimensions, 13-15 (Table 13-6)
bevel gear proportions, 13-8, 13-9
end position of hob, 13-48 (Fig. 13-50)
extra travel, spur gears, 13-61 (Table
feed change gear formulas, 13-56
helical gears, nonparallel shafts, 13-11
index change gear formulas, 13-54,
lead change gear formulas, 13-57
minimum shift in hobbing, 13-51
production time, 13-60
1-17
13-22)
(Table 13-3)
13-56
spur gear proportions, 13-5 (Table 13-
2), 13-7, 13-8
start of modifications, hobbing, 13-42
tooth form systems, hobbing, 13-39
variation allowances, 13-23 (Table 13-
worm gear dimensions, 13-12
advance of grinding wheel per work
angular wheel stiffness, 11-12(Fig. 11-4)
arc of contact, wheel and work, 11-10
breakdown force intensity, 11-14
elasticity number, 11-14
equivalent diameter, 11-13, 11-24
finish feed rate, reciprocate grinding,
grain depth of cut, 11-9
induced force intensity, 11-14
lateral wheel stiffness, 11-12(Fig. 11-4)
mjs vs. rpm, 11-35
plunge grinding velocity, normal inter-
(Fig. 13-41)
13), 13-24
grinding
revolution, 11-14
11-12
face force intensity, 11-14
Equations, grinding (cont.)
power, 11-14
radii of curvature, grinding wheel,
sfm vs. rpm, 11-35
specific power, 11-15
time constant, 11-15
traverse dressing speed, 11-32
wheel sharpness, 11-13
wheel wear parameter, 11-14
work cutting stiffness, 11-14
workspeed, reciprocate grinding, 1I -12
cutter approach, 10-68
cutter speed vs. spindle speed, 10-53
depth of cut, maximum, 10-44 (Fig.
feed rate, 10-53
milling time, 10-68
number of inserts, maximum, 10-36
offset for convex radius, 10-67
peripheral relief, 10-62
power, 10-50
surface finish, theoretical, face milling,
1-25, 1-26 (Fig. 1-41)
surface finish, theoretical, peripheral
milling, 1-26 (Fig. 1-42)
tangential force components, 10-52
tangential load, 10-50, 10-51 (Fig.
changeover costs, 5-16
coolant pump capacity, 4-16
cost per part, minimum, 1-60
cost, total, per part, 1-60
cutting fluid cost, 4-8 (Table 4-1)
cutting ratio, 1-2 (Fig. 1-l), 4-2 (Fig.
cutting temperature vs. cutting speed,
cutting time, 15-37
cycle-time savings, 5-45
efficiency, machine tool, 5-15
extended tool life equation, 1-47
Faraday’s first and second laws, 14-31
film parameter, hydrodynamic lubriflycutting, concave error, 3-39, 3-40
gross power, 1-14
internal rate of return, 5-21
jaw force, multijaw chucks, 8-54
machining cost, 1-60
machining time, 1-60
material hardness vs. tensile strength,
metal removal factor, 1-14
net present value, 5-21
noise exposure, time-weighted average,
Ohm’s law, 14-31 (Table 14-13)
overhead cost, 1-60
overhead cost per part, 1-60
planing time, 7-46
power, net vs. gross, 1-14
productivity ratio, 5-15
reservoir capacity, cutting fluids, 4-16
setup cost, 1-60
specific power consumption, 1-14
Stabler’s Rule, 1-6
surface finish vs. machining cost, 1-22
Taylor’s tool life equation, 1-46
tolerance control, 2-1
toolchanging cost, 1-60
total production time per part, 1-61
ECM, length of gap, 14-31
angular grinding, 11-14
milling
10-67)
10-78)
miscellaneous
4-1)
1-45
(Table 14-13)
cation, 4-36
(Fig. 3-18)
1-57
18-17
nontraditional machining
Equations, nontraditional machining (cont.)
ECM relationships, 14-31(Table 14-13)
ECM, specific metal removal rate, 14-
ECM, volume of metal removed, 14-31
Ohm’s law, 14-31 (Table 14-13)
chip length ratio (see cutting ratio)
coefficient of friction, 1-11
cutting ratio, 1-2 (Fig. 1-l), 4-2 (Fig.
force components, 1-10
friction angle, 1-1 1
shear angle, 1-2 (Fig. 1-1), 1-10
shear strain, 1-3 (Fig. 1-4), 1-10
shear strength, mean, 1-1 I (Table 1-1)
total work, 1-1 1 (Table 1-1)
work done in overcoming friction, 1-1 1
work donc in shear, 1-11 (Table 1-1)
chasers, neck width to chamfer angle,
forming taps, theoretical drill size, 12-94
tapping, chip load per tooth, 12-88
tapping, pitch diameter limit number,
tapping, torque, 12-99
thread percentage calculations, 12-74
31 (Table 14-13)
(Table 14-13)
orthogonal cutting
4-1)
(Table 1-1)
thread cutting
12-58 (Fig. 12-31)
12-84
(Table 12-37)
turning
cutting force vs. depth of cut, feed per
cutting force vs. metal removal factor,
cutting force vs. specific power concutting temperature vs. cutting speed,
effective rake angle, 1-6
extended tool life equation, 1-47
form tool contour, 8-42,8-43
inclination angle, 1-7 (Fig. 1-16)
power, 8-64
surface finish, theoretical, round-nose
(Fig. 3-20)
revolution, 1-18
1-18
sumption, 1-18
1-45
tools, 1-24, 1-25(Fig. 1-40),3-40,3-42
Taylor’s tool life equation, 1-46
tool life vs. temperature, 4-3
undeformed chip thickness, 8-66
unit power, 8-64
ES (see Electro-Stream)
Etchants and etching, chemical
ceramic inserts, 3-32
types, 14-82
Etching mode, ECM, 14-24
Expansion, arbor, I 1-23
Expansion, coefficient of
aluminum, 8-108 (Table 8-26)
bronze, 8-108 (Table 8-26)
cast iron, 8-108 (Table 8-26)
hafnium-coated carbide inserts, 3-31
single-crystal diamond, 3-38
steel, 8-108 (Table 8-26)
tungsten carbide, 8-108 (Table 8-26)
Expansion mandrel, 11-88, 11-89 (Fig. 11-81,
Fig. 11-82, and Fig. I1-83)
Extensive shear, 1-4, 1-5 (Fig. 1-1I )
Extreme-pressure lubrication
cutting fluid additives, 4-4, 4-5
grease, 4-44
industrial lubricant additives, 4-38, 4-47
(Table 4-15)
metalcutting, 4-4
Extrusion dies, manufacturing of, 14-60
1-1 1INDEX
F
Face angle (see Tool geometry)
Face driver, turning, 8-48 (Fig. 8-66)
Face milling
cutters, 10-28
defined, 10-1
milling and centering machines, 15-41 (Fig.
15-35), 15-42 (Fig. 15-36)
speeds and feeds, 10-54 (Table 10-7)
Facing (see also Facing tools)
cutting fluids, 4-10 (Table 4-2)
indexable-insert drills, 9-48,9-49 (Fig.9-38)
milling, 10-1, 15-42
plunge, 15-40
cast cobalt-based alloys, geometry, 3-15
(Table 3-7)
coated carbide
performance vs. uncoated carbide, 3-33
speeds and feeds, 3-33 (Table 3-18)
geometry, 3-47 (Table3-25)
performance vs. carbide, 3-47 (Table
speeds and feeds, 3-47 (Table 3-25)
geometry, 3-44 (Table 3-23)
performance vs. carbide and singlecrystal diamond, 3-44 (Table3-23)
speeds and feeds, 3-44 (Table 3-23)
Facing tools, single-point (see also Facing)
(Table 3-18)
cubic boron nitride
3-25)
polycrystalline diamond
Feed lines, grinding, 11-116
Feed rate, cutting, defined, 8-2(seealso Speeds
Feed units, power
and feeds, machining)
quill-type, 15-80 (Fig. 15-103)
swivel-type, 15-86 (Fig. 15-110)
way-type, 15-79 (Fig. 15-lOl), 15-80 (Fig.
15-102), 15-86 (Fig. 15-109)
Feed wheel (see Regulating wheel)
Feedback circuits, 5-28, 5-32
Felt, hydrodynamic machining, 14-8 (Table
Ferrite
hydrodynamic machining, 14-9 (Table
ultrasonic machining, 14-11 (Table 14-6)
~ Fiberglass and fiberglass composites
hydrodynamic machining, 14-7 (Table
laser cutting, 14-72 (Table 14-23)
laser drilling, 14-68 (Table 14-21)
polycrystalline diamond tools, 3-43
twist drilling, 9-90 (Table 9-20)
Fillet radii, chemical milling, 14-89
Film parameter
boundary regime, 4-38
vs. coefficient of friction 4-38 (Fig. 4-18)
defined, 4-36
mixed-film regime, 4-37
Filtration and filters
cutting fluids, 4-15, 4-20
ECM electrolyte, 14-27
EDM dielectric, 14-48
electrical discharge wire cutting dielectric,
grinding fluids, 11-48
cutting fluids, tests, 4-28
defined, 4-39
lubricants, industrial, 4-39
classification of fires, 18-15 (Fig. 18-8)
computer fires, 18-16
detectors and alarms, 18-15
fire extinguishers, portable, 18-16
planning, 18-16
suppression devices, 18-15
14-3)
14-4)
14-2)
14-6I
Fire point
Fire protection
Fish scale fracture, high-speed steel, 3-9
Fixtures (see Workholding)
Flame cutting, 2-2 (Fig. 2-1)
Flange tightening, grinding wheel, 11-23
Flank wear (see also Tool life and tool wear)
definition, 3-1, 8-76
milling cutters, 10-72
titanium carbide coated carbide, 3-31
tungsten carbide, cemented, 3-26 (Table
turning tools, 8-76
cutting fluids, tests, 4-28
defined, 4-39
lubricants, industrial, 4-39
Flat die thread rolling, 12-131
Flat drills, 9-48 (Fig. 9-36)
Flatness, 2-3 (Fig. 2-3)
Flaws (see Surface finish)
Flexibility, NC, 5-9
Flexible manufacturing (machining) systems
advantages and justification, 15-91 (Fig.
15-112),15-92(Table15-14), 15-93(Table
applications, 15-96 (Fig. 15-113, Fig. 15-
114, and Fig. 15-115), 15-97 (Fig. 15-116
and Fig. 15-117), 15-98 (Fig. 15-118 and
Fig. 15-119)
3-13)
Flash point
(FMS’s)
15-15)
control systems, 15-90
defined, 15-88, 15-89 (Fig. 15-1 11)
material handling, 15-89
operation, 15-90
planning installations, 15-94(Table 15-16)
work stations, 15-88
Flexible tube filters, 4-22
Flexing of coated abrasives, 11-40
Flint, coated abrasive, 11-41
Flood application
cutting fluids, 4-13
electrolyte, electrochemical machining,
cutting fluids, 4-17 (Fig. 4-3), 4-18
grinding fluids, 11-48
comparative ratings, 4-41 (Table 4-9)
greases, 4-46 (Table 4-13)
properties, 4-42
14-34
Flotation
Fluorocarbons
Fly hob (see Flycutters and flycutting)
Fiycutters and flycutting
applications, 13-39
defined, 13-39
jig boring machines, 8-107 (Fig. 8-158)
single-crystal diamond, 3-39
speeds and feeds, 13-53
Flywheels, milling cutters, 10-45
FMS (see Flexible manufacturing systems)
Foaming and antifoamants
cutting fluids, 4-29
industrial lubricants, 4-48 (Table 4-16)
Follower end, broach, 7-24
Follower rests, 8-49, 8-50 (Fig. 8-70)
Following error, NC, 5-43 (Fig. 5-25)
Force, cutting
adaptive control, 5-69
bandsawing, 6-12, 6-24 (Fig. 6-21)
broaching, 7-20, 7-21 (Fig. 7-19), 7-22
chamfered edges, effect with CBN tools,
continuous vs. discontinuous chips, 1-7
cutting fluids, effects of, 1-19, 4-2
vs cutting speed, 1-18
vs. dimensions of cut, 1-18
drills, multiple-lip, high-pressure coolant,
electrical discharge machining, 14-54
hydrodynamic machining, 14-3, 14-6 (Fig.
3-46
9-88.(Fig. 9-98)
14-7)
Force, cutting (cont.)
indexable1insert drilling, 9-80, 9-84 (Fig.
9-961
machkability, as a measure of, 1-42
milling, 10-3
oblique cutting, 1-11
orthogonal cutting
(Fig. 1-20)
coefficient of friction vs. feed rate, 1-12
components, 1-10
force system, 1-9 (Fig. 1-17)
frictional force vs. feed rate, 1-12 (Fig.
mean shear stress on shear plane vs.
work done in cutting vs. feed rate, 1-12
work done in overcoming friction vs.
work done in shearing vs. feed rate,
1-21)
feed rate, 1-12 (Fig. 1-22)
(Fig. 1-25)
feed rate, 1-12 (Fig. 1-24)
1-12 (Fig. 1-23)
practical measurement, 1-15
spade drilling, 9-80, 9-85 (Table 9-19)
symbols, 1-8
vs. tool materials, 1-19
twist drilling, 9-44 (Fig. 9-31), 9-79
ultrasonic machining, 14-8
ultrasonically assisted machining, 14-13
Force intensity, 11-14
Force-feed lubricator, 4-50, 4-51 (Fig. 4-24)
Forced vibration, 8-76
Form tools
circular, 8-40(Fig. 8-53), 8-43,15-19, 15-20
dovetail, 15-33, 15-34 (Fig. 15-27)
flat, 8-40 (Fig. 8-53), 8-41
high-speed steel, grades, 3-10, 3-13
(Fig. 15-10), 15-33
Formica, high-speed steel tools, geometry, 8-
Forming taps (see Tapping and taps)
Formulas (see Equations)
Fracture milling cutters, 10-73
turning tools, 8-76
Frame milling, 10-6 (Fig. 10-7)
Frequency, vibration, ultrasonic machining,
Friction, coefficient of
coatings for carbide inserts, 3-3I (Table
defined, 1-18
vs. feed rate, orthogonalcutting, 1-12(Fig.
vs. film parameter, 4-38 (Fig. 4-18)
orthogonal cutting, 1-1I (Table 1-1)
vs. rake angle, 1-18
reduction of, 1-18
single-crystal diamond, 3-38
cutting ratio, I-2,4-2
energy required, 11-45
force required, 1-11 (‘Table 1-1)
friction zones, 4-2
frictional force vs. feed rate, orthogonal
lubrication, 4-4
tapping, reduction of, 12-106 (Fig. 12-62)
work done in overcoming, 1-1 1 (Table 1-1)
Friction modifiers, industrial lubricants, 4-47
Friction sawing
bandsawing, 6-13, 6-22
circular sawing, 6-36
Fungi and fungi control
cutting fluids, 4-27, 4-34
industrial lubricants, 4-48 (Table 4-16)
29 (Table 8-3)
14-7
3-17)
1-20)
Friction, metalcutting
cutting, 1-12 (Fig. 1-21)
(Table 4-15), 4-48
~~
1-12INDEX
G
G-TRAC cutting
applications, 13-62
cutting tools, 13-63(Fig. 13-64)
machine tools, 13-62, 13-63(Fig. 13-63)
principles, 13-62
Gaging control, 11-105, 15-87
Gang milling, defined, 10-2
Gap lathe, 8-3
Garnet, coated abrasive, 11-41
Gear couplings for reamers, 9-124,9-125 (Fig.
Gear manufacturing (see Gears and gear
Gear rolling and spline rolling
9-129)
manufacturing)
advantages, 13-26
bar stock, 13-29
cylindrical die, 13-27(Fig. 13-19)
finishing
double-die, 13-96
principles, 13-96(Fig. 13-126)
single-die, 13-97
full depth, 13-27
individual blanks, 13-29
materials, 13-28
methods, 13-28
planetary incremental, 13-28(Fig. 13-23)
reciprocating rack, 13-27 (Fig. 13-20 and
Fig. 13-21)
tubular, 13-29
worm rolling, 13-29
application, 13-26
automation, 13-92
crown shaving, 13-91 (Fig. 13-117)
cutting fluid cleanliness, 13-91
cutting fluids, 4-10 (Table 4-2)
principles, 13-87
rack shaving, 13-90, 13-91(Fig. 13-115)
rotary crossed-axis, 13-87(Fig. 13-107j
stock allowance, 13-92(Table 13-33)
accuracy, 13-3
axis positions, 13-3
bevel gear manufacturing
blanks, 13-78
blank inspection, 13-80, 13-81 (Fig.
blank tolerances, 13-80
curved-tooth bevel gears, 13-84
gear types, 13-76 (Fig. 13-86 and Fig.
13-87). 13-77 (Table 13-29)
Gear shaving and shaving tools
Gears and gear manufacturing
13-96)
grinding, 13-95.
machine tools, 13-81,13-82(Fig. 13-97)
straight bevel gears, 13-83
workholding, 13-85
defined, 13-8
drawings, 13-78(Fig. 13-93)
Gleason 20″ straight bevel-gear system,
Cleason spiral bevel gear system, 13-9
nomenclature, 13-8, 13-9 (Fig. 13-7),
special, 13-10
Beveloid gears, 13-13
broaching, 7-32 (Fig. 7-36 and Fig. 7-37),
Concurve gearing, 13-13
Cone drive, 13-12, 13-13(Fig. 13-9)
conjugate action, 13-2(Fig. 13-1)
cutting fluids, 4-10 (Table 4-2)
defined, 13-1
diecasting, 13-25
Fellows face gear drive, 13-13
G-TRAC process, 13-62
gear finishing, principles, 13-86
bevel gears
13-8
13-76
13-26,13-33
Gears and Gear manufacturing (cant.)
grinding, 13-93
helical gears, 13-8, 13-56, 13-57
helical gears, crossed, 13-10
Helicon gearing, 13-13
hobbing, 13-26,13-34
honing, 13-93
Hypoid gears, 13-13, 13-78
lapping, 13-92
milling, 13-26,13-30
nomenclature and symbols, 13-1
photochemical machining, 13-26
pitch surfaces, 13-3, 13-4(Fig. 13-2)
plastic molding, 13-25
powdered metal, 13-25
roll finishing, 13-96
rolling, 13-27
shaping, gear, 7-54, 13-26, 13-63
shaving, 13-87
Spiroid gearing, 13-12
splines, involute, 13-13
spur gears
13-5(Table 13-2)
composite tooth system, 141/2″, 13-4,
defined, 13-3
Fellows full-depth involute system, 200,
Fellows stub-tooth system, 20″, 13-7
fine-pitch, 13-8
full-depth involute system, 141/2O,13-4,
13-5 (Table 13-2), 13-7(Fig. 13-4)
full-depth involute system, 20″ and
25″, 13-7 (Fig. 13-5)
hobbing, 13-54
metric gears, 13-8, 13-71
stub-tooth involute system, 20″, 13-7
13-8
(Fig. 13-6)
stamping and extruding, 13-25
tools, HSS
cutter grinders, 11-95, 11-96(Fig. 11-99)
grades, 3-10
grinding wheels for sharpening, 11-30
worms and worm gears, 13-10,13-12(Table
Zero1 gears, 13-13, 13-77
(Table 11-10)
13-4 and Fig. 13-8)
Gel etchants, 14-82
Geometric tolerances, 2-3 (Fig. 2-3), 2-52
Geometry, tool (see Tool geometry)
Germanium
photo/silk screen resist etchants, 14-84
(Table 14-28)
ultrasonic machining, 14-11 (Table 14-6
and Table 14-7)
Germicides (see Bacteria and bacteria control)
Glass and glass fibers
abrasive cutoff wheels, 11-122(Table 11-23)
carbide cutting tools, classifications, 3-22
(Table 3-11)
cylindrical grinding wheels for, 11-28
(Table 11-8)
drilling, twist, 9-90 (Table 9-20)
hydrodynamic machining of, 14-4 (Table
14-l), 14-9 (Table 14-4)
photo/silk screen resist etchants, 14-84
(Table 14-28)
ultrasonic machining, 14-11 (Table 14-6
and Table 14-7)
Glass wool, hydrodynamic machining, 14-8
Glazing in honing, 11-126
Glossaries (see Nomenclature)
Glue bond coated abrasives, 11-42
Gold, photo/ silk screen resist etchants for, 14-
Grain size
ceramic, cold-pressed, 3-34 (Table 3-19)
ceramic, hot-pressed, 3-34 (Table 3-19)
coated abrasives, 11-41
(Table 14-3)
84 (Table 14-28)
Grain size (cont.)
gear lapping, 13-92
grinding discs, 11-35
grinding wheels, 11-16 (Table 11-2)
vs. root width, thread grinding wheels, 12-
124 (Table 12-59)
vs. thread pitch, thread grinding wheels,
12-I23 (Table 12-58)
ultrasonic machining, abrasive, 14-6
Granite, hydrodynamic machining of, 14-9
Graphic input, 5-46, 5-47 (Fig.5-29)
Graphic plotters, 5-48
Graphite (see also Carbon)
(Table 14-4)
boiling point, 14-49 (Table 14-17)
cubic boron nitride tools, 3-45
elasticity, modulus of, 14-49(Table 14-17)
electrical conductivity, 14-49(Table 14-17)
electrodes, EDM, 14-44, 14-51
heat to vaporize, 14-49 (Table 14-17)
melting point, 14-49 (Table 14-17)
polycrystalline diamond tools. 3-43
tensile strength, 14-49 (Table 14-17)
thermal conductivity, 14-49 (Table 14-17)
ultrasonic machining, 14-11 (Table 14-6)
Graphitizing of single-crystal diamonds, 3-39
Gravity filters, 4-21
Grease
additives, 4-43, 4-47
characteristics, 4-44 (Table 4-11)
defined, 4-42
hardness, 4-45
oil, 4-43
service guidelines, 4-45 (Table 4-12), 4-46
(Table 4-13)
testing, 4-45
thickeners, 4-42
abrasive belt machining, 11-118
accuracy, 2-2 (Fig. 2-1)
adaptive control, 11-50
advantages, 11-1
applications, 11-3
center hole, 11-90
control gaging, 11-105
creep-feed, 11-103
cutoff, abrasive, 11-121
cylindrical, 11-65
distortion caused by, 1-36, 1-37 (Fig. 1-56)
electrical discharge, 14-61
fluids, 11-44
glossary of terms, 11-4
grain depth of cut, 11-9(Fig. 11-1 and Fig.
heat buildup, 11-45
high-speed, 11-100
low stress, 11-104
machine tools, 11-49
manual vs. automatic, 11-65
plunge, 11-11, 11-12(Fig. 11-3), 11-14
reciprocate, 11-12 (Fig. 11-4)
surface integrity
Grinding
11-2)
A M 4 3 4 0 steel, 1-33, 1-35 (Fig. 1-51)
depth of alterations, 1-30 (Table 1-4)
HS-31 cast cobalt-based alloy, 1-33, 1-
types of alterations, 1-28 (Table 1-3)
35 (Fig. 1-50)
surface, 11-50
troubleshooting, 11-109
typical sound levels, 18-25 (Fig. 18-20)
wheel/work conformity, 11-13, 11-24,
wheels, 11-I5
wheelspeed, 11-23
work speed, 11-24
area of contact, 11-45
endfeed, 11-80, 11-81 (Fig. 11-62)
tool, 11-91
11-45
Grinding, centerless cylindricalINDEX
Grinding, centerless cylindrical (cont.)
flow recommendations, grinding fluid, 4-
grain depth of cut, 11-10
infeed, 11-79, 11-81 (Fig. 11-61)
machine tools
14 (Table 4-3)
general-purpose, 11-81, 11-82 (Fig.
production-type, 1 1-81, 11-82 (Fig.
shoe-type, 11-81, 11-83 (Fig. 11-67)
selection of grinding fluids, 11-46 (Table
theory, 11-76
throughfeed, 11-78 (Fig. 11-57 and Fig.
11-58), 11-79 (Fig. 11-59)
wheels, 11-26 (Table 11-7)
Grinding, centerless thread (see Grinding,
Grinding, creep feed
11-64)
11-66)
11-16)
thread)
cylindrical grinding, 11-104
desirable features, 11-103
gear teeth, 13-94
process characteristics, 11-103(Fig. 11-110)
surface grinding, 11-104
area of contact, 11-45
capabilities, 11-66, 11-67(Table 11-17)
center vs. centerless, 11-66 (Fig. 11-45)
engine lathe attachments, 8-9, 8-10 (Fig.
external techniques, 11-66
flow recommendations, grinding fluids, 4-
grain depth of cut, 11-9(Fig. 11-1and Fig.
grinding fluids, 11-46(Table 11-16)
internal techniques, 11-82
machine tools
cam grinders, 11-73
centerless, 11-76
chucking-type, 11-74,11-75(Fig. 11-53)
crankpin grinders, 11-75
internal, 11-82
multiple wheel, 11-72(Fig. 11-51)
plain, O D center-type, 11-69 (Fig.
roll grinders, 11-70
universal, OD center-type, 11-69
defined, 11-66(Fig. 11-44)
quantitative relationships, 11-14
wheel/ work configuration, 11-11, 11-
wheel/workinterface, 1I-l3(Fig. 11-5)
defined, 11-66(Fig. 11-44)
wheel/ work configuration, 11-12(Fig.
Grinding, cylindrical
8-12)
14(Table 4-3)
11-2)
11-47)
plunge
12 (Fig. 11-3)
traverse
11-4)
troubleshooting, 11-110 (Table 11-20)
wheels, general, 11-28(Table 11-8)
wheels, tool room, 11-30 (Table 11-10)
workholding, 11-87
configuration, 11-50, 11-51(Fig. 11-18)
feeding, 11-58(Fig. 11-30)
machine tools
Grinding, disc
double-disc, 11-59(Fig. 11-31and Fig.
vertical spindle, single-disc, 1 1-58(Fig.
11-32)
11-30)
principles, 11-57
troubleshooting, 11-115 (Table 11-22)
accuracy, 14-62
applications, 14-61
dielectric fluids, 14-62
machine tools, 14-61 (Fig. 14-59), 14-62
material removal rate, 14-62
Grinding, electrical discharge (EDG)
Grinding, EDG (cont.)
power, 14-62
principles, 14-61
spark gap, 14-62
wheel dressing, 14-62(Fig. 14-60)
wheel speed, 14-62
accuracy, 2-2 (Fig. 2-1)
applications, 14-19, 14-20(Fig. 14-21)
electrolytes, 14-18
machine tools, 14-19
principles, 14-18 (Fig. 14-20)
surface integrity
Grinding, electrochemical (ECG)
depth of alterations, 1-30 (Table 1-4)
distortion, 1-37, 1-38 (Fig. 1-58)
tooling, 14-20
wheels, 14-18
applications, 14-16
current density, 14-16
machine tools, 14-17
power, 14-16
principles, 14-16
surface integrity
Grinding, electrochemical discharge (ECDG)
depth of alterations, 1-30 (Table 1-4)
distortion, 1-37, 1-38 (Fig. 1-58)
Grinding fluid (see also Cutting fluid)
acceptability tests, 11-45
application, 11-46
economic evaluation, 4-8 (Table 4-1)
filtration, 11-48
flow recommendations, 4-14 (Table 4-3)
functions, 11-44
low-stress grinding, 11-105(Table 11-19)
safety, 18-13
selection, 11-45, 11-46(Table 11-16)
wheel-fluid interaction, 11-47
bevel gears, 13-95
formed wheels, 13-93(Fig. 13-119)
grinding fluid selection, 11-46(Table 11-16)
involute-generation, 13-94
stock removal, 13-96
Grinding, hand disc, 2-2 (Fig. 2-1)
Grinding, internal
Grinding, gear
area of contact, 11-45
chucking type vs. centerless type, 11-85
flow recommendations, grinding fluid, 4-
gaging, 11-108 (Fig. 11-113, Fig. 11-114,
grinding fluid selection, 11-46(Table 11-16)
machine tools
14(Table 4-3)
and Fig. 11-115)
long bore, 11-84(Fig. 11-70)
manual feed, 11-83(Fig. 11-68)
planetary, 11-85, 11-86(Fig. 11-73)
semiautomatic, 11-84(Fig. 11-69)
universal, 11-84, 11-85(Fig. 11-71)
vertical, 11-84, 11-86(Fig. 11-72)
above-center, 11-87(Fig. 11-77)
centerless, 11-85, 11-86(Fig. 11-75)
chucking, 11-85, 11-86(Fig. 11-74)
climb, 11-86(Fig. 11-75)
on-center, 11-85, 11-86(Fig. 11-76)
wheel/ work configuration
Grinding, jig
accessories, 11-97
applications, 11-97
vs. jig borers, 11-96
machine tools, 11-97 (Fig. 11-101), 11-98
numerical control, 11-100
operating practices, 1 1-99
wheels, 11-98
Grinding, low-stress
depth below surface, 11-105 (Fig. 11-112)
fatigue-endurance effects, 11-104 (Fig.
operatingparameters, 11-105(Table 11-19)
(Fig. 11-102)
11-I11)
Grinding, low-stress (cont.)
Grinding, offhand
residual stress, 1-40 (Fig. 1-61)
accuracy, 2-2 (Fig. 2-1)
wheels, I 1-30 (Table 11-10)
Grinding, periphery (see Grinding, surface)
Grinding ratio
defined, 11-15, 11-24
high-speed grinding, 11-100, 11-102 (Fig.
high-speed steel, 3-7, 3-12 (Fig. 3-6)
high-speed steel, powdered metal, 3-12
11-109)
(Fig. 3-6)
Grinding, surface
area of contact, 11-45
creepfeed applications, 11-104
flow recommendations, grinding fluid, 4-
grain depth of cut, 11-10
grinding fluid selection, I 1-46(Table 11-16)
machine tools
heavy-duty, horizontal spindle, 11-53,
11-54 (Fig. 11-22 and Fig. 11-23)
horizontal-spindle wheelface, 11-56
light-duty, horizontal spindle, 11-52
medium-duty, horizontal spindle, 11-
multihead, index table, 11-56 (Fig.
multihead, rotary table, vertical spindle,
oscillating-wheel, 11-56
reciprocating table, vertical-spindle,
rotary-table, horizontal-spindle, 11-53,
rotary-table, vertical-spindle, 11-54,
throughfeed wheel-face, 11-56, 11-57
periphery grinding, 11-50, 11-51 (Fig.
S-N curve, 1-38 (Fig. 1-59)
troubleshooting, 11-114 (Table 11-21)
wheel-face grinding, 11-50, 11-51 (Fig. 11-
wheels, general, 11-25 (Table 11-6)
wheels, tool room, 11-30 (Table 11-10)
workholding methods, 11-60
Grinding, thread
applications, 12-124
centerless
14 (Table 4-3)
(Fig. 11-19)
52, 11-53(Fig. 11-21)
11-28)
11-55, 11-56 (Fig. 11-27)
11-54, 11-55 (Fig. 11-25)
11-55 (Fig. 11-24)
11-55 (Fig. 11-26)
(Fig. 11-29)
11-17)
17), 11-53
methods, 12-123(Fig. 12-87)
principles, 12-122, 12-123(Table 12-58)
wheel selection, 12-I24
defined, 12-114
fluids, 11-46 (Table 11-16)
grinding wheels
dressing, 12-1 20 (Fig. 12-82)
specifications, 12-119 (Table 12-57)
types, 12-118 (Fig. 12-78)
hardness of workpieces, 12-1 14
machine tools
attachments and accessories, 12-115
structural features, 12-114
types, 12-115
speeds and feeds, 12-125 (Table 12-60)
surface finish, 12-127 (Table 12-62)
troubleshooting, 12-126
broach, 11-96
broaches, 7-35
carbide, 3-24, 8-69
cast cobalt-based alloys
Grinding, tool
practice, 3-16, 8-69
wheels and wheel speeds, 3-18 (Table
3-9)
drills, 9-96
1-14INDEX
Grinding, tool (cont.)
G-TRAC cutters, 13-63
gear shaper cutters, 13-74
high-speed steel tools, 8-69, 11-30 (Table
machine tools
11-10)
hobs, 13-60
drill grinders, 11-94 (Fig. 11-94 and
end-mill, 11-95 (Fig. 11-98)
face-mill, 11-94, 11-95 (Fig. 11-97)
gear cutter, 11-95, 11-96 (Fig. 11-99)
optical projection form, 11-92, 11-93
tool and cutter, 11-92,ll-93 (Fig. 11-92)
Fig. 11-95)
(Fig. 11-93)
milling cutters, 10-62
polycrystalline diamond, 3-45, 8-70
reamers, 9- 127
safety, 18-13
single-crystal diamond, 3-40, 8-70
Swiss-type automatics, 15-27
taps, 11-96 (Fig. 11-loo), 12-103(Fig. 12-
58 and Fig. 12-59)
thread chasers, 12-64
wheels, 11-30 (Table 11-10)
Grinding, wheel-face (see Grinding, surface)
Grinding wheels (see Wheels, grinding)
Gripping force, chuck, 8-53, 8-54 (Fig. 8-80)
Grooving and grooving tools
carbide titanium grades, 3-28
cutting fluids, 4-10 (Table 4-2)
planing, 7-47
Guards, machine (see Safety)
Gundrills and gundrilling
cutting fluids
fluid flow recommendations, 4-14
selection, 4-10 (Table 4-2)
(Table 4-3)
external-chip-removal, 9-54, 9-55 (Fig.
internal-chip-removal, 9-56, 9-61 (Fig. 9-
speeds and feeds, 9-58 (Table 9-11), 9-89
ultrasonic, 14-13, 14-15 (Fig. 14-15)
9-49)
56, Fig. 9-57 and Fig. 9-58)
Gypsum board, hydrodynamic machining of,
14-8 (Table 14-3)
H
Hacksawing, power (seealso Blades, hacksaw)
advantages, 6-3
blades, 6-5
cost and performance, 6-2 (Table 6-1)
cuttability tests, 1-43
cutting fluids, 4-10 (Table 4-2), 6-7
defined, 6-3
kerf, 6-2
limitations, 6-3
machine tools
capacity, 6-1
column-type, 6-3 (Fig. 6-1)
cycle, 6-4
drives, 6-4
feed systems, 6-4
hinge (scissor) type, 6-4 (Fig. 6-3)
horizontal-type, 6-4 (Fig. 6-2)
optional equipment, 6-5
materials, workpieces, 6-1
safety, 6-11
speeds and feeds, 6-7, 6-8 (Table 6-2)
troubleshooting, 6-11 (Table 6-3)
workholding, 6-6
Hafnium carbide, 3-20
Hafnium nitride coating for carbide, 3-31
Half-round drills, 9-48 (Fig. 9-37)
Halogen-containing compounds
(Table 3-17)
comparative ratings, 4-41 (Table 4-9)
Halogen-containing compounds (cont.)
properties, 4-41
Halogenated polyaryls
comparative ratings, 4-41 (Table 4-9)
properties, 4-42
Hand oiling, industrial lubricants, 4-49
Handling, workpiece, 5-11 (see also Manual
loading/ unloading)
Hard-wired controls, 5-23
Hardcopy terminals, 5-48
Hardening, surface, HSS, 3-10
Hardness (see also Hardness, hot)
alteration in machining, 1-30 (Table 1-4),
aluminum oxide, 14-6
boron carbide, 14-6
carbide, 3-2 (Fig. 3-1)
carbide vs. polycrystalline diamond, 3-42
carbide vs. single-crystal diamond, 3-38
cast alloy, 3-2 (Fig. 3-1)
ceramics, 3-2 (Fig. 3-1), 3-34 (Table 3-19)
coated carbide, 3-30
coatings for carbide, 3-3I (Table 3-17)
cubic boron nitride, 14-6
diamond abrasive, 14-6
grease, 4-45
high-speed steel, 3-2 (Fig. 3-1), 3-7 (Table
martensite, untempered, 1-29, 1-32 (Fig.
optimum for machining of steel, 1-5I
polycrystalline diamond, 3-2 (Fig. 3-I),
sawing, optimum range, 6-1
silicon carbide, 14-6
single-crystal diamond, 3-38
steel, alloy, 1-52 (Table 1-11)
surface finish, effects upon, 1-23
vs. tensile strength, 1-57
titanium carbide, 3-26 (Table 3-14), 3-27
tungsten carbide, 3-19 (Fig. 3-8), 3-27 (Fig.
tungsten carbide,alloyed, 3-20,3-2 I (Table
water for cutting fluids, 4-23, 4-26 (Table
Hardness, hot (see also Hardness)
carbides, 3-3 (Fig. 3-2)
carbon tool steel, 3-3 (Fig. 3-2)
cast cobalt-based alloys, 3-14
ceramic cutting tools, 3-3 (Fig. 3-2)
coatings for carbide, 3-31
defined, 3-3
high-speed steel, 3-3 (Fig. 3-2)
tungsten carbide, alloyed, 3-20
carbides, 3-3 (Fig. 3-2)
carbon tool steel, 3-3, (Fig. 3-2)
cast cobalt-based alloys, 3- 14
ceramic cutting tools, 3-3 (Fig. 3-2)
defined, 3-3
high-speed steel, 3-3 (Fig. 3-2)
Hastelloys (see Superalloys)
Hazardous Substances Acts, 4-32
HBM’s (see Boring machines, horizontal)
HDM (see Hydrodynamic machining)
Headchanging machines, 15-72, 15-73 (Fig.
15-88,Fig. 15-89,and Fig. 15-90), 15-74(Fig.
15-91), 15-75 (Fig. 15-92)
Heat to vaporize (from room temperature),
14-49 (Table 14-17)
Heat treatment
1-35
3-2)
1-4.5)
3-42
(Fig. 3-11)
3-11)
3-10)
4-4)
Hardness, recovery (see also Hardness, hot)
annealing, HSS, 3-8
austenitizing, HSS, 3-8 (Table 3-3)
tolerance control, 2-49
defined, 1-32, 1-34 (Fig. 1-48)
depth of, machining, 1-30 (Table 1-4)
Heat-affected zone
Helix angle
drills, twist, 9-45 (Fig. 9-33)
single-point turning of threads, 12-52
(Table 12-25)
H F (see Hone-Forming)
Higbee cut, 12-2, 12-3 (Fig. 12-1)
High-speed machining
principles, 11-100
safety, 11-35
applications, 10-70
attachments, 10-22
grinding
milling
turning, 8-75
High-speed steel (see Steel, high-speed)
High-temperature alloys (see Superalloys)
History
cutting fluids, 4-1
cutting tool materials
aluminum oxide (ceramics), 3-32
cast cobalt-based alloy, 3-14
coated carbide, 3-30
development, 3-3, 3-4 (Fig. 3-3)
high-speed steel, 3-4
high-speed steel, powdered metal, 3-11
titanium carbide, 3-25
tool steel, carbon and low-alloy, 3-4
tungsten carbide, cemented, 3-16
direct numerical control, 5-29
involute splines, 13-14
programmable controllers, 5-2
safety, 18-1
surface grinders, I 1-50
Unified thread specifications, 12-8
applications, 13-54
cutting fluids, 4-10 (Table 4-2)
forms by hobbing, 13-34,13-35(Fig.13-33)
gears and splines
angular hob setting, 13-51(Fig. 13-53)
climb vs. conventional, 13-35 (Fig.
crown and taper, 13-58
double-helical gear hobbing, 13-57
eliminating flats, 13-48
feed directions in hobbing, 13-51
feeds and speeds, 13-52, 13-53(Fig. 13-
55), 13-55(Table 13-20)
finish pitch hobbing, 13-58
fixtures, 13-48
gear-hob limits, standard, 13-40, 13-43
(Table 13-18)
generation, 13-34
grinding wheels for HSS, P / M metal
hob centralizing, 13-50
hob principles, 13-38
hob shifting, 13-50
hob-tooth form modifications, 13-41
materials, hob, 3- 14, 13-39
multiple-thread hobs, 13-39, 13-48
nomenclature and symbols, 13-39, 13-
nondifferential helical gear hobbing,
preshave hob modifications, 13-42
principles, 13-25(Fig. 13-18), 13-26
single-thread hobs, 13-39
special hob-tooth forms, 13-45
spline shaft hobs, 13-46, 13-47 (Fig.
splines, 13-54
spur gears, 13-54
tooth forms and depths, 13-39, 13-41
(Table 13-16), 13-42(Table 13-17)
wormgear hobs, 13-47, 13-48(Fig. 13-
Hobs and hobbing
fly tools, 13-39, 13-53
13-34)
hobs, 11-30(Table 11-10)
40 (Fig. 13-40)
13-56
13-45)
48), 13-59, 13-60
production time, 13-60
1-1 5INDEX
Hobs and hobbing (cont.)
Hone-Forming (HF)
sharpening, 13-60, 13-61, 13-62
applications, 14-23
machine tools, 14-23
principles, 14-23 (Fig. 14-24)
Honing (see also Honing tools)
accuracy, 2-2 (Fig.2-1)
cutting fluid flow recommendations, 4-14
cutting fluid selection, 11-46(Table11-16),
vs. electrochemical honing, 14-22 (Table
gear teeth, 13-93
heavy stock removal, bore finish control,
(Table 4-3)
11-127(Table 11-24)
14-11)
11-125
Honing, electrochemical (ECH)
applications, 14-21
vs. conventional honing, 14-22 (Table
gap thickness, 14-22
machine tools, 14-22
power, 14-22
principles, 14-21 (Fig. 14-23)
abrasives, 11-129
electric expansion, 11-127(Fig. 11-119)
rough and finish combination, ll-l28(Fig.
square push rod, 11-128 (Fig. 11-120)
Hook angle (see Rake angle)
Hook tooth, 6-19, 6-20 (Fig. 6-17)
Horizontal boring machines (HBM’s) (see
Boring machines, horizontal)
Horizontal boring, milling, drilling, and tapping machines (see Boring machines, horizontal)
Horizontal plate pressure filters, 4-22
Hot hardness (see Hardness, hot)
Hot isostatic pressing (see Isostatic pressing;
Hot machining
14-11)
Honing tools (see also Honing)
11-121)
hot)
applications, 4-3
components, 8-75 (Fig. 8-104)
defined, 4-3
applications, 4-57
cleanliness, 4-58
comparative performance, 4-57 (Table
fire-resistance fluids, 4-58
function, 4-56
handling, 4-58
properties, 4-59 (Table 4-18)
stability, 4-58
types, 4-56
Hydraulic operation, boring machines, 8-78
Hydrocarbons, synthetic
applications, 4-42 (Table 4-10)
comparative ratings, 4-41 (Table 4-9)
properties, 4-40
Hydrochloric acid electrolyte, 14-25, 14-26
Hydrocyclones, 4-19, 4-21 (Fig. 4-7), 11-48
Hydrodynamic lubrication, 4-35, 4-36 (Fig.
Hydrodynamic machining (HDM)
cutting speeds, 14-3, 14-7(Table 14-2)
equipment, 14-3
forces, 14-3
nozzles, 14-2
power, 14-3, 14-5(Fig. 14-5 and Fig. 14-6)
principles, 14-1, 14-2 (Fig. 14-1 and Fig.
rake angle, 14-2 (Fig. 14-2), 14-3
standoff distance, 14-2(Fig. 14-2), 14-3
temperature, 14-3
water pressure, 14-3
Hydraulic fluids
4-17)
(Table 14-12)
4-14)
14-2)
Hydrodynamic machining (cont.)
workpiece materials, 14-2, 14-4(Table 14-1)
Hydrodynamic spindle bearings, I 1-49
Hydrogen, removal, electrochemical machinHydrostatic bearing spindle, 8-80
Hypoid gears, 13-13
ing, 14-35
I
Impact strength (see Strength, impact)
Inactive cutting oils, 4-5
Inclination angle
milling, 1-6, 1-7 (Fig. 1-15)
turning, 1-6
Incoloys (see Superalloys)
Inconel (see Superalloys)
Indexing fixture
(Fig. 11-43)
grinding, 11-63, 11-64 (Fig. 11-42), 11-65
turning, 8-97, 8-98 (Fig. 8-135)
Induction brazing, tipped tools, 8-70
Inscribed circle (IC), indexable inserts, 8-38
Inserts, indexable
boring, 8-87
drilling, 9-48
milling, 10-30, 10-31 (Fig. 10-46 and Fig.
spade drilling, 9-51
threading, 12-49
trepanning, 9-64, 9-66 (Fig. 9-68 and Fig.
turning, 8-32
10-47)
9-69)
Inservice oil, defined, 4-53
Inspection
bevel gear blanks, 13-80,13-8 1(Fig. 13-96)
grinding wheels, 11-18
Insulation properties of dielectric fluids, 14-45
Interactive computer processing, 5-47
Interface, programmable, 5-32
Intergranular attack
defined, 1-29
depth of, machining, 1-30 (Table 1-4)
electrical discharge machining, 14-50
Internal grinding (see Grinding, internal)
Internal rate of return, 5-21
Interpolation, 5-31, 5-39
Interpolators, 5-37
Iron
boiling point, 14-49(Table 14-17)
elasticity, modulus of, 14-49(Table 14-17)
electrical conductivity, 14-49(Table 14-17)
heat to vaporize, 14-49(Table 14-17)
melting point, 14-49(Table 14-17)
tensile strength, 14-49(Table 14-17)
thermal conductivity, 14-49(Table 14-17)
I S 0 standards (see Standards)
Isostatic pressing, cold
cemented tungsten carbide, 3-18
ceramics, 3-34
high-speed steel, powdered metal, 3-11
Isostatic pressing, hot
cemented tungsten carbide, 3-18
ceramics, 3-32, 3-34
high-speed steel, powdered metal, 3-11
J
Jet flushing EDM, 14-47
Jig boring (see Boring, jig)
Jig grinding (see Grinding, jig)
Jigs (see Workholding)
Justification (see Economic evaluation)
K
K-land
ceramic, 3-36 (Fig. 3-14)
K-land (cont.)
Kerf
titanium carbide, 3-29
bandsawing, 6-2 (Table 6-1)
circular sawing, 6-2 (Table 6-I), 6-36
electrical discharge wire cutting, 14-59
laser beam cutting, 14-67,14-69(Fig. 14-66)
plasma arc cutting, 14-78
power hacksawing, 6-2, 6-3
Keyseater, 7-49
Keyway
broaching, 7-26(Fig. 7-23),7-30,7-31 (Fig.
milling cutter, 10-25(Fig. 10-38)
shaping, 7-49
7-34)
Kinematic viscosity (see Viscosity)
Knurling tools, screw machining, 15-19
Knurls, broaching, 7-29
1
Lag error, NC, 5-43 (Fig. 5-25)
Languages
computer-assisted part programming, 5-
programmable controllers, 5-5, 5-6 (Fig.
accuracy, 2-2 (Fig. 2-1)
gears, 13-92
accuracy, 2-2 (Fig. 2-1)
applications, 14-65
cutting, 14-65, 14-67, 14-69 (Fig. 14-67),
14-72 (Table 14-23)
defined, 14-63
drilling, 14-66, 14-67 (Table 14-20), 14-68
(Table 14-2I)
vs. electron beam machining, 14-65
machine tools, 14-67, 14-74 (Fig. 14-70)
power, 14-66
principles, 14-63, (Fig. 14-61 and Fig.
pulse shapes, 14-64 (Fig, 14-63)
reflectivity, 14-64
safety, 14-70
setup, 14-65 (Fig. 14-64)
spot size, 14-66
surface integrity, 1-30 (Table 1-4)
types, 14-63, 14-64 (Table 14-19)
accuracy, 8-6 (Table 8-2)
contouring (tracer), 8-11, 8-12 (Fig. 8-16,
Fig. 8-17), 8-14 (Fig. 8-19), 8-15 (Fig.
defined, 8-1, 8-2 (Fig. 8-1)
engine, 8-3
NC/CNC, 8-17, 8-19 (Fig. 8-26 and Fig.
8-27), 8-20 (Fig. 8-28)
single-spindle automatic
applications, 15-5, 15-6 (Fig. 15-6)
attachments, 15-3(Fig. 15-2), 15-4(Fig.
15-3 and Fig. 15-4)
machine design, 15-1, 15-2 (Fig. 15-1
and Table 15-1)
toolholders, 15-5
workholding, 15-5 (Fig. 15-5)
Lay (see Surface finish)
LBM (see Lasers and laser beam machining)
Lead
photo/silk screen resist etchants, 14-84
(Table 14-28)
polycrystalline diamond tools, 3-43
Lead attachments, milling machine, 10-24
Lead time, NC, 5-9
Lead-angle tools, 8-26
46, 5-55
5-1)
Lapping
Lasers and laser beam machining
14-62)
Lathes and lathe tools (see also Turret lathes,
Turning, Boring, etc.)
8-20)
types, 8-3
1-16INDEX
Leadscrew, 5-28
Leather, hydrodynamic machining of, 14-8
(Table 14-3)
Light pipe effect, 14-66
Limit switches, 5-27
Line-index machines (see Shuttle-type special
Linear interpolation, 5-39
Link lines, 15-76 (Fig. 15-93 and Fig. 15-94)
Lip angle, 8-28
Load per unit area, bearings, 4-35
Loading/ unloading
manual, 16-1
pick-and-place manipulators, 16-9
programmable robots, 16-14
single-spindle automatic lathes, 15-4 (Fig.
single-spindle automatic screw machines,
15-22 (Fig. 15-13)
vertical boring machines and turret lathes,
15-57, 15-58 (Fig. 15-62), 15-60 (Fig. 15-
machines)
15-4)
68), 15-61
Location, hole
boring, 8-79 (Table 8-20)
tolerance control, 2-1
Location, workpiece
methods, 9-70, 10-46 (Fig. 10-71)
principles, 9-69
tolerance control, 2-1
Lockout procedures, 18-8, 18-9 (Fig. 18-6),
Low-alloy tool steel, 3-4
Lubrication and lubricants, industrial
additives, 4-38, 4-47
application methods, 4-49
conformal and nonconformal surfaces, 4-
elastohydrodynamic, 4-36 (Fig. 4-15)
grease, 4-42
hydraulic fluids, 4-56
hydrodynamic, 4-35,4-36 (Fig. 4-14).
naphthenic oil, 4-40
paraffinic oil, 4-40
properties, 4-38
recycling and disposal, 4-53
solid, 4-47 (Table 4-1.5)
synthetic oil, 4-40
18-10 (Fig. 18-7)
35 (Fig. 4-13)
Lubrication mechanism of cutting fluids, 4-4
M
Machinability
chemical composition, 1-58
coefficient of friction, 1-57
cuttability tests, 1-43
cutting speed vs. tool life, 1-46 (Fig. 1-62)
cutting temperature tests, 1-42
defined, 1-40
dimensions of cut vs. tool life, 1-47
electrochemical machining, 14-26, 14-27
hardness vs. tensile strength, 1-57
hardness, workpiece, 1-51
high-speed steel, 3-7 (Table 3-2)
microstructure, 1-58
observing tool failure, 1-44
power consumption tests, 1-43
ratings, 1-48
vs. rollability, 13-30
simulated production tests, 1-43
strain-hardenability, 1-57
strength, tensile, 1-51
surface finish tests, 1-42
symbols, 1-40
temperature vs. tool life, 1-45
test standardization, 1-43
thermal properties, 1-58
tool force tests, 1-42
(Fig. 14-26)
Machinability (cont.)
tool geometry vs. tool life, 1-47
tool life and tool wear tests, 1-41
tool life specification, 1-44
tool wear, causes, 1-44
adaptive control, 5-66
glossary of terms, 5-70
manual data input (MDI), 5-43, 15-44
numerical control
advantages, design, 5-12
advantages, manufacturing, 5-8
computer numerical control, 5-23
direct numerical control, 5-29
justification, 5-13
machine configurations, 5-34
selection, 5-31
part programming, 5-40
part programming, computer-assisted, 5-44
programmable controllers, 5-2
sequence controllers, 5-1
Machine controls
Machine screw recesses, 9-138 (Table 9-49)
Machine tools
abrasive belt machines, 11-119, 11-20(Fig.
bandsaws, 6-13
boring, 8-80
broaches, 7-6
cam grinders, 11-73
center drilling and facing machines, 15-40,
15-41 (Fig. 1.5-34 and Fig. 15-35), 15-42
(Fig. 15-36)
center-column, 15-78 (Fig. 15-99)
circular saws, 6-36
combination-operation, 15-76, 15-77 (Fig.
crankpin grinders, 11-75
cutoff, abrasive, 11-124(Fig. 11-118)
cylincrical grinders, 11-66
dial-type (rotary-index), 15-78(Fig. 15-98)
disc grinders, 11-57
double-end, 15-77
drilling, 9-4
electrical discharge grinders, 14-62
electrical discharge machines, 14-42 (Fig.
electrical discharge wire cutters, 14-60
electrochemical discharge grinding, 14-17
electrochemical grinding, 14-19, 14-21 (Fig.
electrochemical honing, 14-22 (Table
electrochemical machining, 14-33
electrochemical turning, 14-35
electrode orbiting electrical discharge
machining, 14-55
electrode rotating electrical discharge
machining, 14-55
electron beam machines, 14-39, 14-41
flexible manufacturing (machining) systems, 15-88, 15-89 (Fig. 15-111), 15-91
(Fig. 15-112), 15-92 (Table 15-14), 15-93
(Table 15-15), 15-94(Table 15-16), 15-96
(Fig. 15-113, Fig. 15-114, and Fig. 15-
115), 15-97(Fig. 15-116and Fig. 15-117),
15-98 (Fig. 15-118 and Fig. 15-119)
G-TRAC cutting, 13-62, 13-63(Fig. 13-63)
gear gashing 13-32 (Fig. 13-29)
gear rolling, 13-28 (Fig. 13-23)
grinders, gear, 13-94
hacksaws, power, 6-3
headchanging machines, 15-72, 15-73(Fig.
15-88, Fig. 15-89 and Fig. 15-90), 15-74
(Fig. 15-91), 15-75 (Fig. 15-92)
hobbing, 13-36 (Fig. 13-35), 13-37 (Fig.
13-36 and Fig. 13-37)
Hone-Forming, 14-23
11-116)
15-95)
14-41), 14-54 (Fig. 14-52)
14-22)
14-11)
Machine tools (cont.)
horizontal boring machines (HBM’s), 15-
42, 15-43(Fig. 15-37and Fig. 15-38), 15-
44 (Fig. 15-39), 15-45(Fig. 15-40and Fig.
15-41), 15-46 (Fig. 1.5-42and Fig. 15-43),
15-47 (Fig. 1.5-44 and Fig. 15-45), 15-48
(Fig. 15-46 and Fig. 15-47), 15-49 (Fig.
15-48 and Fig. 15-49) 15-50 (Fig. 15-50,
Fig. 13-51 and Fig. 15-52), 15-51 (Fig.
15-53 and Fig. 15-54), 15-52 (Fig. 15-55,
Fig. 15-56 and Table 15-11)
hot machining, 8-75 (Fig. 8-104)
hydrodynamic machining, 14-3
installation, 1-22
internal grinders, 11-83
jig borers, 8-101
jig grinders, 11-96
keyseaters, 7-49
laser machining systems, 14-67, 14-74(Fig.
lathes, 8-3
lathes, threading, 12-48
link lines, 15-76(Fig. 15-93and Fig. 15-94)
machining centers, 15-63, 15-64 (Fig. 15-
73), 15-65 (Fig. 15-74 and Fig. 15-75),
15-66 (Fig. 1.5-76 and Fig. 15-77), 15-67
(Fig. 15-78 and Fig. 15-79), 15-68 (Fig.
15-80, Fig. 15-81, Fig. 15-82 and Fig.
15-83), 15-70(Fig. 15-84and Fig. 15-85),
15-71 (Fig. 15-86 and Fig. 15-87)
milling, 10-8
modular construction units, 15-79(Fig. 15-
100 and Fig. 15-lOl), 15-80 (Fig. 15-102
and Fig. 15-103)
multiple-spindle automatic bar and chucking machines, 15-29, 15-30 (Fig. 15-19),
15-31 (Fig. 15-20 and Fig. 15-21), 15-32
(Fig. 15-22 and Fig. 15-23), 15-33 (Fig.
15-24 and Fig. 15-25), 15-34 (Fig. 15-26,
Fig. 15-27, Fig. 15-28 and Fig. 15-29),
15-36 (Fig. 15-30 and Fig. 15-31), 15-38
(Fig. 15-32and Fig. 15-33), 15-39 (Table
multiple-spindle, vertical, automatic
chucking machines, 15-62 (Fig. 15-71),
15-63 (Fig. IS-72)
NC machine configurations, 5-34
noise control, 18-21, 18-25 (Fig. 18-20)
planers, 7-38
plasma arc cutting, 14-81
plasma arc turning, 14-81
roll grinders, 11-70
rolling, gear, 13-97, 13-98 (Fig. 13-130)
rotary ultrasonic, 14-12
shaped tube electrolytic machining, 14-36
shapers, 7-49
shapers, gear, 13-64 (Fig. 13-66), 13-76
shavers, gear, 13-89 (Fig. 13-111)
shuttle (line-index), 15-77 (Fig. 15-96)
single-spindle automatic lathes, 15-1, 15-2
(Fig. 15-1 and Table 15-1), 15-3(Fig. 15-
2), 15-4 (Fig. 15-3 and Fig. 15-4), 15-5
(Fig. 15-5), 15-6 (Fig. 15-6)
single-spindle automatic screw machines,
15-7(Fig. 15-7), 15-8 (Table 15-2), 15-12
(Table 1S-3), 15-13 (Table 15-4 and Fig.
15-8), 15-14 (Fig. 15-9), 15-15(Table 15-
5), 15-16(Table 15-6), 15-18(Table 15-7),
15-20(Fig. 15-10), 15-21(Fig. 15-1I), 15-
22 (Fig. 15-12, Fig. 13-13,and Fig. 15-14)
dotters, 7-49
spline rolling, 13-27 (Fig. 13-20), 13-28
(Fig. 13-23)
surface grinders, 11-50
Swiss-type automatic screw machines, 15-
23, 15-24(Fig. 15-15), 15-25 (Fig. 15-16),
15-26 (Table 15-8), 15-27 (Table 15-9),
15-28 (Fig. 15-17 and Fig. 15-18)
14-70)
15-10)
1-17INDEX
Machine tools (cont.)
tapping machines, 12-75
thread grinders, 12-114
thread rolling
cylindrical-die, 12-132
flat-die, 12-131
planetary, 12-134
threading machines, 12-54, 12-55 (Fig.
tool grinders, 11-92
transfer machines
12-24)
in-line, 15-82, 15-83 (Fig. 15-105), 15-
rotary, 15-81 (Fig. 15-104)
84 (Fig. 15-106 and Fig. 15-107)
trepanning, 9-11
trunnion-type, 15-77, 15-78 (Fig. 15-97)
ultrasonic machining, 14-9
vertical boring machines and turret lathes,
15-53, 15-54 (Fig. 15-57, Fig. 15-58 and
Fig. 15-59), 15-55 (Fig. 15-60 and Fig.
15-61), 15-56(Table 15-12), 15-57 (Table
15-13), 15-58(Fig. 15-62 and Fig. 15-63),
15-59 (Fig. 15-64, Fig. 15-65, and Fig.
15-66), 15-60(Fig. 15-67and Fig. 15-68),
15-61 (Fig.15-69 and Fig. 15-70)
worm rolling, 13-30 (Fig. 13-26 and Fig.
broaches, 7-1 1
drilling, 9-12
rotary ultrasonic, 14-12
safety, 11-34
Machines (see Machine tools)
Machining centers
advantages, 15-63
applications, 15-64
automatic toolchangers, 15-67, 15-68 (Fig.
construction, 15-65, 15-67(Fig. 15-79), 15-
controls, 15-69
horizontal-spindle, 15-65 (Fig. 15-75), 15-
66 (Fig. 15-76 and Fig. 15-77), 15-67(Fig.
tooling and toolholders, 15-69, 15-70(Fig.
unmanned, 15-72
vertical-spindle, 15-64 (Fig. 15-73), 15-65
workhandling, 15-71 (Fig. 15-86 and Fig.
13-27)
Machine tools, portable
15-81, Fig. 15-82 and Fig. 15-83)
68 (Fig. 15-80)
15-78)
15-84 and Fig. 15-85)
(Fig. 15-74)
15-87)
Machining economics
advanced models, 1-63
application, 1-61
cost factors, 1-60
cutting speed for minimum cost, 1-60
decision criteria, 1-59
maximum production rate, 1-61
symbols, 1-59
Machining, nontraditional
chemical milling, 14-83
defined, 14-1
electrical discharge grinding, 14-61
electrical discharge machining, 14-42
electrical discharge wire cutting, 14-59
Electro-Stream, 14-36
electrochemical discharge grinding, 14-16
electrochemical grinding, 14-18
electrochemical honing, 14-21
electrochemical machining, 14-24
electrochemical turning, 14-35
electrode rotating electrical discharge
machining, 14-55
electromechanical, 14-15
electron beam machining, 14-37
Hone-Forming, 14-23
hydrodynamic, 14-1
laser beam machining, 14-63
Machining, nontraditional (cont.)
no-wear electrical discharge machining,
photochemical machining, 14-89
plasma arc, 14-71
rotary ultrasonic, 14-9
shaped tube electrolytic machining, 14-35
ultrasonic, 14-5
ultrasonically assisted, 14-12
14-56
Macros, 5-32
Magnesium and alloys
(Table 8-4)
86 (Table 8-22)
carbide tools, single-point, geometry, 8-30
carbide-tipped boring tools, geometry, 8-
cut-and-peel mask etchants, 14-86 (Table
cutting fluids, 4-10 (Table 4-2), 4-13
drilling, laser, 14-67(Table 14-20)
drilling, twist, 1-19, 1-20 (Fig. 1-36), 9-90
face and back-off angles, HSS broaches,
grinding fluids, 11-46(Table 11-16)
milling, 1-2O(Fig. 1-36), 10-35(Table 10-2)
photo/silk screen resist etchants, 14-84
planing, 1-20(Fig. 1-36)
reaming, carbide-tipped, 9-1I4(Table 9-39)
tapping, 12-90,12-91 (Table 12-45), 12-102
(Table 12-51)
thread chasing, I2-58,12-59 (Table 12-28),
12-63, 12-64(Table 12-31)
threading tools, high-speed steel, geometry,
12-49, 12-50(Table 12-24)
Magnetic chuck for turning, 8-62
Magnetic separator (see Separator, magnetic)
Magnetic tape, disc, drum, 5-26
Making coat, 11-40, 11-42
Man-made diamond, 3-42
Mandrels
14-29)
(Table 9-20), 9-103
7-18 (Table 7-4)
(Table 14-28)
grinding, 11-88
turning, 8-48, 8-49 (Fig. 8-67, Fig. 8-68,
and Fig. 8-69)
Manganese and manganese alloys, milling of,
10-35(Table 10-2)
Manipulators, pick-and-place (see Pick-andplace manipulators)
Manual data input
defined, 5-43
milling machines, 10-14, 10-15(Fig. 10-20)
Manual loading/ unloading
applications, typical, 16-6(Table 16-3)
attributes, 16-8(Table 16-4), 16-9
labor cost, 16-4
NC equipment, 5-11
operator skill, 16-4
output volumes, 16-3(Fig. 16-3), 16-4(Fig.
process time vs. output volume, 16-4(Fig.
process time requirements, 16-2,16-3(Fig.
reduction of, 16-5(Table 16-1), 16-8
workpiece configuration, 16-2
workpiece weight, effects of, 16-4(Fig. 16-
6), 16-5 (Table 16-2), 16-9
drilling, twist, 9-90 (Table 9-20)
hydrodynamic machining, 14-9 (Table
Martensite in high-speed steel, 3-9
Maskants, cut-and-peel, 14-82, 14-86 (Table
Material flow, NC, 5-1I
Material removal rate
16-4)
16-5)
16-2)
Marble
14-4)
14-29)
abrasive belt machining, 11-118
chemical machining, 14-84 (Table 14-28),
14-86(Table 14-29) 14-89
Material removal rate (cont.)
circular sawing, 6-44 (Table 6-9), 6-45
electrical discharge grinding, 14-62
electrical discharge machining, 14-50
electrical discharge wire cutting, 14-60
Electro-Stream, 14-36
electrochemical discharge grinding, 14-17
electrochemical honing, 14-22
electrochemical machining, 14-31 (Table
electrochemical turning, 14-35
electron beam machining, 14-39, 14-40
(Fig. 14-39)
G-TRAC cutting, 13-62
grinding, 11-24
milling, 10-52(Table 10-5)
plasma arc cutting, 14-78
plasma arc turning, 14-79, 14-80 (Table
shaped tube electrolytic machining, 14-36
ultrasonic assisted machining, 14-14(Table
ultrasonic machining, 14-7, 14-11 (Table
Materials, cutting tool (see Cutting tool
material)
MDI (see Manual data input and Machine
controls)
Mean dimension, 2-4 (Fig. 2-4)
Melting point
copper, 14-49 (Table 14-17)
graphite, 14-49 (Table 14-17)
iron, 14-49(Table 14-17)
tungsten, 14-49 (Table 14-17)
capacity, 5-33
types, 5-25
Metal bond wheels, defined, 11-16
Metal removal factor
vs. cutting speed, 1-18
defined, 1-14
Metal removal rate (see Material removal
Metalcutting, theory of
economics, 1-59
forces and power, 1-10
geometry of chip formation, 1-1
machinability, 1-41
surface finish, 1-21
surface integrity, 1-27
(Table 6-10)
14-13)
14-27)
14-9)
14-6 and Table 14-7)
Memory, CNC
rate)
Metric screw threads (see Screw threads,
Mica, glass bonded, ultrasonic machining of,
Micrograin carbide (see Carbide, micrograin)
Microsine plate, 8-104(Fig.8-149),8-106(Fig.
Milling (see also Milling cutters and inserts)
abreast, multiple-part, 10-$10-6 (Fig. 10-6)
accuracy, 2-2 (Fig. 2-l), 10-7
applications
metric)
14-11 (Table 14-6)
8-154)
gears and splines, 13-26, 13-30
helical surfaces and contours, 10-70
high-speed, 10-70
process planning, 10-68
production, 10-68
slotting, 10-70
threading, 10-70, 12-109
workpiece materials, 10-69
arbors, 10-22
crane and parking, 10-22
dividing heads, 10-24 (Fig. 10-37)
high-speed, 10-22
index bases, 10-23
lead equipment, 10-24
attachments
Chucks, 10-23
1-18INDEX
Milling, attachments (cont.)
multiple-spindle, 10-24
polygon for Swiss-type automatics,
precision readout, 10-24
rack-milling, 10-22
rotary tables, 10-22
slotting, 10-22
threading, 10-22, 12-109
turret for screw machining, 15-21
universal milling, 10-21
vertical milling 10-21,10-22(Fig. 10-34)
vises, 10-23 (Fig. 10-36)
box or frame, 10-6 (Fig. 10-7)
cam, 10-2
chemical, 14-83
chip formation, 10-3
crankshaft, 10-3
cutter life and failure, 10-72
cutters, 10-24
cutting fluids
15-26
applications, 10-60
fluid flow recommendations, 4-14
methods, 10-61, 10-62 (Fig. 10-7Y)
nozzle size and orientation, 4-15
selection, 4- I0 (Table 4-2), 10-61
(Table 4-3)
cutting speed, 10-53, 10-54 (Table 10-7),
defined, 10-1
diesinking, 10-3
electron beam machining, 14-38
end, 10-2, 10-28
engine lathe attachment, 8-9, 8-10 (Fig.
face, 10-1
facing, double-end, 15-41 (Fig. 15-35),
facing with indexable-insert drills, 9-48,9-
feed rate, 10-53, 10-54(Table 10-7), 10-60
gang, 10-2
gear, 10-2
gear gashing, 13-32
index, 10-7
jig boring machines, 8-107
machine tools
10-60
8-11)
15-42
49 (Fig. 9-38)
compound universal, 10-10
crankshaft, 10-20 (Fig. 10-33)
fixed-bed-type, horizontal, 10-11 (Fig.
fixed-bed-type, saddle, 10-13 (Fig.
fixed-bed-type, two-spindle, 10-12(Fig.
fixed-bed-type, vertical, 10-12, 10-13
(Fig. 10-17)
gantry-type, 10-17, 10-18 (Fig. 10-28)
hand-fed, 10-8
high-speed, 10-10
plain, 10-9 (Fig. 10-10)
planer-type, 10-17(Fig. 10-26and Fig.
planetary, 10-21
programmable, 10-14, 10-15 (Fig.
ram-type, 10-10 (Fig. 10-13)
ram-type, special, 10-18(Fig. 10-29)
rotary, 10-21
tracer controlled, 10-13, 10-14 (Fig.
traveling-column, 10-19(Fig. 10-30and
turret-ram, 10-10, 10-11 (Fig. 10-14)
universal, 10-9 (Fig. 10-11)
vertical, 10-10 (Fig. 10-12)
10-15)
10-18)
10-16)
NC/CNC, 10-14
I 0-2 7)
10-20)
10-19)
Fig. 10-31), 10-20 (Fig. 10-32)
peripheral, 10-1
planetary, 10-3
Milling (cont.)
plunge, 10-3
power
efficiency, 10-53 (Table 10-6)
factors, 10-50
feed force, 10-52
metal removal rate, 10-52 (Table 10-5)
spindle, 10-50
tangential load, 10-50, 10-51 (Fig.
progressive, 10-6
rotary, 10-7 (Fig. 10-9)
rotary ultrasonic, 14-12
safety, 10-74
sharpening of cutters, 10-62
side, 10-2
single-piece, 10-5
sound levels, typical, 18-25 (Fig. 18-20)
specific power consumption, 1-19, 1-20
(Fig. 1-36)
speed vs. feed, 10-53
straddle, 10-2
string multiple-part, 10-5, 10-6 (Fig. 10-5)
surface finish, 1-25, 1-26 (Fig. 1-41), 10-7,
surface integrity
10-78)
10-74
built-up edge effects in carbide milling
of AISI 4340 steel, 1-32 (Fig. 1-44)
depth of alterations, 1-30 (Table 1-4)
distortion, 1-36, 1-37 (Fig. 1-57)
general considerations, 10-8
tool wear vs. residual stress in AISI
4340 steel, 1-35 (Fig. 1-52)
types of alterations, 1-28 (Table 1-3)
thread, 10-3, 12-109
time study analysis, 10-73(Table 10-12)
transfer base, 10-7
troubleshooting, 18-74,lO-75 (Table 10-13) ’
up and down, 10-3, 10-4 (Fig. 10-1)
workholding
capacity of fixtures, 10-48 (Fig. 10-74)
clamps, 10-46
details, fixture, 10-48, 10-49(Fig. 10-75
fixture design, 10-49 (Fig, 10-77)
fixture types, 10-46, 10-47 (Fig. 10-72)
locating workpieces, 10-45, 10-46(Fig.
selection of fixtures, 10-48
and Fig. 10-76)
I0-71)
Milling cutters and inserts (see also Milling)
carbide, titanium, grades, 3-26, (Table 3-
carbide, tungsten, grades, 3-22 (Table3-11)
cast cobalt-based allays, speeds and feeds,
ceramics, geometry, 3-35
cutter life and failure, 10-72
defined, 10-24
effectivediameter, 10-32, 10-33(Fig. 10-50)
end mills
14), 3-28
3-17 (Table 3-8)
carbide-tipped, 10-39
cutting ends, 10-38
deflection, 10-38, 10-74
high-speed steel, grades of, 3-10
indexable-insert, 10-39
insertable-blade, 10-39
number of flutes, 10-38
sharpening, 10-64, 10-65 (Fig. 10-84)
solid, 10-38, 10-39 (Fig. 10-62), 10-40
speeds and feeds, 10-56 (Table 10-8)
tool geometry, 10-29
entry angle, 10-33 (Fig. 10-51 and Fig.
face-mill grinders, 11-94, 11-95(Fig. 11-97)
gashing cutters, 13-33
gear cutters, 13-3I
hand of rotation, 10-32
high-speed steel
grades, 3-10
10-52)
Milling cutters and inserts, high-speed steel
(cont.)
grinding wheels for sharpening, 11-30
high-speed steel, powdered metal, grades,
indexable-insert
(Table 11-10)
3-13
configuration, 10-29 (Fig. 10-42)
corner geometry, 10-36
geometry, 10-33
lead angle, 10-36
pitch, 10-36
rake angle, 10-33, 10-34 (Fig. 10-53
through Fig. 10-56), 10-35 (Table
retention of, 18-12
tool materials, 10-37
10-2)
inserted blade, 10-29
mounting
offace-type, 10-41, 10-67(Table 10-11)
of shaft-type arbors, 10-44
of shank-type, 10-40 (Fig. 10-63)
of shell-type, 10-41 (Fig. 10-64)
nomenclature, 10-31
polycrystalline diamond, applications, 3-43
sharpening
dulling limits, 10-62
of end mills, 10-64, 10-65 (Fig. 10-84)
of face-milling cutters, 10-64 (Fig.
of form-relieved cutters, 10-63, 10-64
(Fig. 10-82)
of grinding wheels, 10-67
inspection, 10-67
of machines, 10-66
of new cutters, 10-62
of peripheral cutters, 10-62, 10-63(Fig.
runout, 10-67 (Table 10-11)
of staggered-tooth cutters, 10-62
10-83)
10-80 and Fig. 10-81)
single-crystal diamond, 3-39
solid, 10-28 (Fig. 10-39, Fig. 10-40, and
thread milling, 12-111
types and styles, 10-24, 10-25 (Fig. 10-38)
Fig. 10-41)
Milling planer, 7-39
Mist lubrication
cutting fluid application, 4-I5
lubricants, industrial, application, 4-53,4-
54 (Fig. 4-30)
Mixed-film lubrication, 4-37 (Fig. 4-17)
Modem, 5-27
Modular units for special machines, 15-67
(Fig. 15-78), 15-79 (Fig. 15-100 and Fig.
101), 15-80 (Fig. 15-102 and Fig. 15-103),
Modulus of elasticity (see Elasticity, modulus
Mold manufacturing, electrical discharge wire
Molybdenum and alloys
15-85
of)
cutting, 14-59
abrasive cutoffwheels, 11-122(Table11-23)
cut-and-peel mask etchants, 14-86 (Table
electron beam machining, 14-40 (Fig.
photo/silk screen resist etchants, 14-84
tapping, 12-90, 12-91 (Table 12-45)
14-2Y)
14-35))
(Table 14-28)
Mother of pearl, ultrasonic machining of, 14-
Mounting, grinding wheel, 1 I -I 8
Multifunction machines, 15-1
Multiple-spindle automatic bar and chucking
machines (see Bar and chucking machines,
multiple-spindle automatic)
10 (Table 14-5), 14-11 (Table 14-6)
~
1-1 9INDEX
N
Naphthenic oils, 4-40
National Institute for Occupational Safety
and Health, 18-1
NC (see Numerical control and computer
numerical control)
Nd:glass laser, 14-63, 14-64 (Table 14-19)
Nd:YAG laser, 14-63, 14-64(Table 14-19)
Negative-rake inserts (see Tool geometry)
Net present value, 5-21
NiHard (see Cast iron)
Niobium carbide
characteristics, 3-20
extended tool life equation, exponents, 1-
Niobium, cut-and-peel mask etchants for, 14-
86 (Table 14-29)
Nitrosamine, 4-33
No-wear electrical discharge machining
(EDM)
47 (Table 1-8)
applications, 14-56, 14-57
electrode coating, 14-57
electrode polarity, 14-57
limitations, 14-57
overcut, 14-57, 14-58 (Fig. 14-54)
principles, 14-56
procedures, 14-57
surface finish, 14-57, 14-58 (Fig. 14-55)
theory, 14-56
control methods
Noise control
changes in equipment, 18-21
machining operations, 18-22
maintenance, 18-22
new machines, 18-22
citation, 18-23
compliance guidelines, 18-24
compliance plan, 18-23
consultants, 18-25
feasibility studies, 18-24
inspection, 18-23
notice of contest, 18-23
progress reports, 18-24
request for extension, 18-24
defined, 18-17
ear protection, 18-22(Table 18-7)
lasers, 14-71
noise exposure vs. noise emission, 18-17
noise standards, OSHA, 18-17 (Table 18-
peak exposure, 18-18
sources of noise
Fig. 18-16)
control program
6), 18-25 (Fig. 18-20)
fans and blowers, 18-20(Fig. 18-15and
gears, 18-18 (Fig. 18-10)
high-velocity air, 18-18, 18-19 (Fig.
hydraulic pumps, 18-19,18-20 (Fig. 18-
materials handling, 18-21 (Fig. 18-18
motors, 18-20 (Fig. 18-17)
typical sound levels, machine tools, 18-
18-11)
13 and Fig. 18-14)
and Fig. 18-19)
25 (Fig. 18-20)
time-weighted average exposure, 18-17
bevel gears, 13-9 (Fig. 13-7)
broach tooth geometry, 7-13 (Fig. 7-10)
broaching, 7-12 (Table 7-2)
drills, spade, 9-52 (Fig. 9-42)
drills, twist, 9-14, 9-15 (Fig. 9-15)
electrical discharge machining, 14-42
gears, 13-1
grinding, 11-4
machine controls, 5-70
machine rebuilding, 17-1
Nomenclature
Nomenclature (cont.)
milling cutters, 10-28 (Fig. 10-39 and Fig.
reamers, 9-107, 9-109 (Fig. 9-1 10)
retrofitting, 17-5
single-point tools, 8-26
solid taps, 12-81
splines, 13-14
threading, 12-1
10-41), 10-39 (Fig. 10-62)
Nomex core, hydrodynamic machining of, 14-
Nonconformal and conformal surfaces, 4-35
Nontraditional machining (see Machining,
Norbide (see Boron carbide)
Normal curve, 2-10 (Fig. 2-8)
Normal flow EDM, 14-45, 14-46 (Fig. 14-43)
Normal force intensity, 11-13 (Fig. 11-6)
Nose radius
boring tools, 8-85
cemented tungsten carbide, 3-21
ceramic, 3-35 (Table 3-21)
cubic boron nitride, 3-47
inserts, 8-37
milling cutters, 10-37
polycrystalline diamond, 3-43
shaping tools, 7-50 (Fig. 7-60 and Fig. 7-
61), 7-51 (Fig. 7-62)
single-crystal diamond, 3-39
single-point tools, 8-29
7 (Table 14-2)
(Fig. 4-13)
nontraditional)
Nose wear, titanium carbide-coated carbide,
Notching
3-31
milling cutters, 10-73
turning tools, 8-76
advantages
Numerical control and computer numerical
control
accuracy, 5-10
control of machining time, 5-9
cost estimating, 5-11
cutting tools, 5-10
flexibility, 5-9
interchangeability, 5-11
machine utilization, 5-10
material flow time, 5-11
planning, 5-8
productivity, 5-11
prototypes, 5-12
safety, 5-11
scheduling, 5-9
setup and lead time, 5-9
tooling costs, 5-10
workpiece handling, 5-11
bandsawing, 6-15 , 6-18
circular sawing, 6-37, 6-38 (Fig. 6-26)
computer numerical control
definition, 5-23
diagnostics, 5-23
hard-wired, 5-23
selection, 5-31
soft-wired, 5-23, 5-24 (Table 5-16)
system elements, 5-25
direct numerical control, 5-29
drilling, 9-4, 9-9
EDM machines, 14-55
electrical discharge wire cutting, 14-61
electron beam machining, 14-41
fire protection, 18-16
hobbing, 13-36
horizontal boring machines (HBM’s),
hydrodynamic machining, 14-4
jig boring, 8-102
jig grinding, 11-100
justification
VS. DNC, 5-23
15-44
direct labor, 5-14
Numerical control and computer numerical
control, justification (cont.)
general considerations, 5-14
in-plant transportation, 5-19
inspection, 5-19
internal rate of return, 5-21
inventory, 5-16
maintenance, 5-20
net present value, 5-21
programming, 5-18
scope, 5-13
tool and fixtures, 5-15
tool consumption, 5-16, 5-17 (Fig. 5-2)
tool setting, 5-18
laser drilling and cutting, 14-70
machine tool configurations, 5-34
milling, 10-14
programming, computer-assisted
advantages, 5-44
elements, 5-45
input devices, 5-46
integration, 5-54
language, 5-46,5-55
output devices, 5-48
procedures, 5-49
storage devices, 5-48
system selection, 5-52
trends, 5-54
programming, manual
input requirements, 5-41
fundamentals, 5-40
manual data input, 5-43
retrofit methods, 17-6
single-spindle automatic screw machines,
Swiss-type automatic screw machines, 15-
thread milling, 12-110, 12-111(Fig. 12-71)
turning, 8-17
Nut mandrels, 11-89(Fig. 11-84and Fig. 11-
15-23
28 (Fig. 15-17 and Fig. 15-18)
85), 11-90(Fig. 11-86)
0
Occupational Safety and Health Act
cutting fluids, 4-33
history, 18-1
impact of, 18-11
noise control program, 18-23
noise standards, 18-17(Table 18-6)
safety check list, machine guarding, 18-11,
Offset tools, 8-26
Oil and oiling (see Cutting fluids and lubriOil particle size, cutting fluids, water-miscible,
Oiliness agents, industrial lubricants, 4-47
Oily waste, defined, 4-53
Oldham coupling, 9-124, 9-125 (Fig. 9-129)
One-way broaching machine, 7-10
Open-side planer, 7-38 (Fig. 7-41)
Operator interface, CNC, 5-26
Optical projection form grinder, 11-92, 11-93
Optical tracing systems, hydrodynamic
Orbiting electrode EDM, 14-55
Organic esters
18-12(Table 18-5)
cation and Lubricants, industrial)
4-25
(Table 4-15), 4-48
(Fig. 11-93)
machining, 14-3
applications, 4-42 (Table 4-10)
comparative ratings, 4-41 (Table 4-9)
general, 4-40
properties, 4-40
force system, 1-9(Fig. 1-17)
geometry, 1-1
Orthogonal cutting model
OSHA (see Occupational Safety and Health
Act)
1-20INDEX
Overcut
conventional EDM, 14-50
electrical discharge wire cutting, 14-59(Fig.
no-wear EDM, 14-57, 14-58 (Fig. 14-54)
titanium carbide, 3-26
tool wear, 1-45
14-57),14-60
Oxidation and oxidation resistance
Oxychloride bond wheels, defined, 11-16
P
PAM (see Plasma arc machining)
Paper
hydrodynamic machining, 14-8(Table 14-
laser cutting, 14-72 (Table 14-23)
3), 14-9 (Table 14-4)
Parabolic interpolation, 5-39
Paraffinic oils, 4-40
Parallelism, 2-3 (Fig. 2-3)
Part surface programming, 5-44 (Fig. 5-26)
Particle board (see Wood, compressed)
Particle size (see Grain size)
Peak-to-valley roughness (see Surface finish)
Pearlite, lamellar, 1-58
Penetration rate, twist drills (see also Material
removal rate)
coolant-fed, 9-45, 9-46 (Fig. 9-34)
solid, 9-45, 9-46 (Fig. 9-34)
Penetration tests, grease 4-45
Perfluoropolyglycols
comparative ratings, 4-41 (Table 4-9)
properties, 4-42
Perforation by electron beam machining, 14-38
Perpendicularity, 2-3 (Fig. 2-3)
Pesticide Act, cutting fluids, 4-34
pH (see Acidity)
Phase transformation, 1-29, 1-32 (Fig. 1-45),
1-33(Fig. 1-46)
AISI 4340 steel, 1-32 (Fig. 1-45)
defined, 1-29
depth of, machining, 1-30 (Table 1-4) .
maraging steel, 18%nickel, 1-33(Fig. 1-46)
applications, 4-42 (Table 4-10)
comparative ratings, 4-41 (Table 4-9)
hydraulic fluids, 4-57, 4-58
properties, 4-41
Photochemical machining
accuracy, 14-90 (Table 14-30), 14-91
applications, 14-89
fundamentals
Phosphate esters
photographic-resist, 14-90
screen-printed resist, 14-91
gear manufacturing, 13-26
multiple parts, 14-92
principles, 14-89
undercut, 14-91
tooling, 14-91
workholding, 14-92
applications, 16-12
axes of motion, 16-10, 16-11 (Fig. 16-9)
cam-driven, 16-10 (Fig. 16-8)
capabilities, 16-11
defined, 16-9
limitations, 16-12
motion drive, 16-9
peripheral enhancements, 16-12
pneumatic, 16-9 (Fig. 16-7)
programming, pnuematic units, 16-10
American National Standard
Pick-and-place manipulators
Pilot, broach, 7-24
Pipe threads
applications, 12-22
joint configurations, 12-22, 12-23(Fig.
12-7)
American National Standard Taper
Pipe threads, American National Standard
Taper (cont.)
applications, 12-22
basic dimensions, 12-23, 12-25 (Table
form, 12-22, 12-23, 12-27 (Fig. 12-8)
applications, 12-27
internal, 12-32 (Table 12-14)
taper, 12-30(Table 12-12),12-31(Table
12-13), 12-32 (Fig. 12-9)
internal straight threads in pipe couplings
applications, 12-23
basic dimensions, 12-23, 12-27 (Table
12-8)
Dryseal
12-9)
mechanical straight
free-fitting, 12-27, 12-28 (Table 12-10)
loose-fitting for hose couplings, 12-27
loose-fitting with locknuts, 12-27, 12-
29 (Table 12-11)
tapping, 12-104
broaches, 7-14
hacksaw blades, 6-6
saw bands, 6-21
saw blades, 6-43 (Fig. 6-36)
Pitch, tooth
Pitting, depth of, machining, 1-30(Table 1-4)
Planer mill, 10-17
Planetary milling
defined, 10-3
machine tools, 10-21
Planetary thread rolling, 12-134
Planing (see also Planing tools)
applications, 7-47
cut time, estimating, 7-46
cutting fluids, 4-10 (Table 4-2)
finishing cuts, 7-41
machine tools
adjustable convertible open-side, 7-38
capacity, 7-39
convertible open-side, 7-38
double-cut, 7-39
double-housing, 7-38 (Fig. 7-40)
milling planer, 7-39
open-side, 7-38 (Fig. 7-41)
principles, 7-38
speeds and feeds, 7-46 (Table 7-10)
tools, 7-39
work layout, 7-43
workholding, 7-42
carbide
Planing tools (see also Planing)
grades, 3-22 (Table 3-11)
types, 7-41, 7-42 (Fig. 7-49 and Fig.
double-cutting, 7-40 (Fig. 7-46),7-41 (Fig.
finishing, 7-41
gang, 7-41 (Fig. 7-48)
geometry, 7-44 (Table 7-9)
plain, 7-39 (Fig. 7-42and Fig. 7-43)
reach, 7-40 (Fig. 7-45)
setting, 7-43
undercutting, 7-39, 7-40 (Fig. 7-44)
7-50)
7-47)
Planning (see Process planning)
Plasma arc machining (PAM)
accuracy, 2-2 (Fig. 2-1)
cutting
bevel, 14-76(Fig. 14-74)
cutting rate, 14-78
edge squareness, 14-78
gas mixture, 14-78
gouging, 14-76
grooving, 14-76
hole piercing, 14-75
kerf width, 14-78
machine tools, 14-81
nozzle size, 14-77
Plasma arc machining, cutting (cont.)
power, 14-77, 14-79 (Table 14-26)
stack cutting, 14-75
standoff distance, 14-78
troubleshooting, 14-77 (Fig. 14-76)
advantages, 14-76
gases, 14-79
machine tools, 14-81
material removal rate, 14-79, 14-80
power, 14-80 (Table 14-27)
setup, 14-76 (Fig. 14-75)
surface finish, 14-80
surface integrity, 14-80
principles, 14-71, 14-74 (Fig. 14-71)
turning
(Table 14-27)
water swirl injection, 14-75 (Fig. 14-72)
Plasma, electrical discharge machining, 14-48,
14-49 (Fig. 14-50)
Plastic deformation
defined, 1-28
depth of, 1-30 (Table 1-4)
milling cutters, 10-73
turning tools, 8-76
Plastically deformed debris
defined, 1-28
depth of, 1-30 (Table 1-4)
Plastics
abrasivecutoffwheels, 11-122(Table11-23)
carbide cutting tools
classifications, 3-22 (Table 3-11)
speeds and feeds, 3-25 (Table3-12)
tungsten grades, 3-21 (Table-3-10)
ceramic tools, geometries, 3-35(Table3-21)
chasers, rake angle, 12-58, 12-59 (Table
cubic boron nitride tools, 3-45
cutting fluids, 4-10 (Table 4-2),4-13
drilling, small hole, 9-89
drilling, twist, 9-38, 9-90 (Table 9-20),
gears, 13-25
grinding wheels
centerless, 11-26 (Table 11-7)
cylindrical, 11-28 (Table 11-8)
hydrodynamic machining, 14-7 (Table 14-
2), 14-8.(Table 14-3), 14-9 (Table 14-4)
laser cutting, 14-72(Table 14-23)
laser drilling, 14-68 (Table 14-21), 14-69
(Table 14-22), 14-70 (Fig. 14-68)
milling, 10-35(Table 10-2)
milling, end, 10-56 (Table 10-8)
polycrystalline diamond tools, 3-43
reaming, HSS reamers, 9-128 (Table9-44)
tapping, 12-90,12-91 (Table12-45), 12-102
12-28)
9-106
(Table 12-51)
Plunge grinding (see Grinding, cylindrical)
Plunge milling, defined, 10-3
Plywood, hydrodynamic machining of, 14-7
(Table 14-2), 14-8 (Table 14-3)
PM (Powder metallurgy process) (see Cast
cobalt-based alloys)
Point-to-point NC, 5-34
Pointed-nose tools, 8-26
Polar compounds, additives for cuttingfluids,
4-4, 4-5
Polarity, EDM, 14-49
Polishing
accuracy, 2-2 (Fig. 2-1)
ECM mode, 14-24
Polycrystalline diamond cutting tools
advantages, 3-42
applications, 3-43, 3-44 (Table3-23)
boring tools, 8-84
carbide, compared with, 3-42, 3-44 (Table
cutting fluid compatibility, 4-9
defined, 3-41
3-23)
1-21INDEX
Polycrystalline diamond cutting tools (cont.j
indexable-insert milling cutters, 10-38
limitations, 3-42
resharpening, 3-45
single-crystal diamond, compared with, 3-
42, 3-44 (Table 3-23)
speeds and feeds, 3-43, 3-44 (Table 3-23)
surface finish effects, 1-24
tool geometries, 3-43, 3-44 (Table 3-23)
turning tools, 8-25
types, 3-42
Polyester hydrodynamic machining of, 14-8
(Table 14-3)
Pol~glycol, 4-40
comparative ratings, 4-41 (Table 4-9)
hydraulic fluids, 4-57, 4-58
properties, 4-40
abrasive cutoff wheels for, 11-122 (Table
carbide cutting tools, classifications, 3-22
grinding discs for, 11-39 (Table 11-15)
grinding wheels for cylindrical, 11-28
Porcelain
1 1-23)
(Table 3-11)
(Table 11-8)
Position, tolerance 2-3 (Fig. 2-3)
Positioning NC, 5-35
Positive filters, 11-48
Positive-rake inserts (see Tool geometry)
Post-processing treatments, 1-35
Postprocessor, 5-33, 5-45, 5-61
Pot broaching and pot broaches
machines, 7-11 (Fig. 7-8)
manufacturing of, 14-60
tools, 7-28 (Fig. 7-27 and Fig. 7-28)
Potassium chloride electrolyte, 14-25
Pour point
defined, 4-39
depressants, 4-48 (Table 4-16)
naphthenic oil, 4-40
paraffinic oil, 4-40
Powdered metal high-speed steel (see Steel,
Powdered metal parts, tapping of, 12-102
Power
high-speed, powdered metal)
(Table 12-51)
adaptive control, 5-69
drilling, spade, 9-81,9-85 (Table 9-19)
drilling, twist, 9-79
electrical discharge grinding, 14-62
electrical discharge wire cutting, 14-60
Electro-Stream, 14-36
electrochemical discharge grinding, 14-16
electrochemical grinding, 14-19
electrochemical honing, 14-22
electrochemical machining, 14-3I
electron beam machining, 14-39, 14-40
(Table 14-16)
gross, defined, 1-14
hobbing, 13-38
hydrodynamic machining, 14-3, 14-5(Fig.
indexable-insert drilling, 9-80,9-82 (Table
laser beam machining, 14-66
machinability, as a measure of, 1-43
metal removal factor, defined, 1-14
milling, 10-50
multiple-cutter trepanning tools, 9-88 (Fig.
multiple-lip, high-pressure coolant drills,
9-88 (Fig. 9-97)
net, defined, 1-14
plasma arc cutting, 14-77
plasma arc turning, 14-80 (Table 14-27)
plunge grinding, 11-14
shaped tube electrolytic machining, 14-36
specific (or unit), defined, 1-14
14-5 and Fig. 14-6)
9-18), 9-84 (Fig. 9-95)
9-100)
Power (cont.)
thread chasing, 12-64, 12-65(Table 12-32)
turning, 8-64
electrical discharge machining, 14-52(Fig.
electrical discharge wire cutting, 14-61
electrochemical machining, 14-34
Precoat ultrahigh filtration, 4-22, 4-25 (Fig.
Premanufacture Notification Program for
Preparatory functions, NC, 5-43
Pressboard (see Wood, compressed)
Pressure
Power supply
14-51), 14-53 (Table 14-18)
4-11), 1 1-49
cutting fluids, 4-33
coolant, gundrilling, 9-58 (Table 9-11)
water, hydrodynamic machining, 14-3, 14-
5 (Fig. 14-3)
Pressure filters
cutting fluids, 4-21
grinding fluids, 11-49
Pressure switches, 5-27
Printed circuit board (see Circuit board)
Probes, 5-33
Process planning
flexible manufacturing systems, 15-94
milling, 10-68
multiple-spindle automatic bar and chucking machines, 15-37, 15-38 (Fig. 15-32
and Fig. 15-33)
numerical control, 5-8
tolerance charting, 2-1
(Table 15-16)
Processors, 5-45
Productivity
broaching, 7-1
NC equipment, 5-11
ratio, 5-15
Profile milling
cutters, 10-28
speeds and feeds, 10-54 (Table 10-7)
Profile of a line, 2-3 (Fig. 2-3)
Profile of a surface, 2-3 (Fig. 2-3), 2-53
Programmable controllers
advantages, 5-3
applications, 5-7
defined, 5-2
dialects, 5-7
future developments, 5-7
history, 5-2
languages, 5-5, 5-6 (Fig. 5-1)
PC vs. computer, 5-2
PC vs. relays, 5-3
selection, 5-4
Programmable robots (see Robots and robotProgressive dies, 14-45
Progressive (nibbling-type) broach, 7-26
Proximity switches, 5-27
Pull end, broach, 7-24
Pulldown internal broaching machines, 7-9
Pullup internal broaching machines, 7-9
Pulsed flushing EDM, 14-47
Pumps, cutting fluid
capacity, 4-16
high pressure, 9-11
proportioning, 4-27
ics)
Punch cards, 5-26
Pushdown internal broaching machines, 7-9
Q
Quartz (see Silicon carbide)
Quick-change tooling for drilling, 9-68, 9-69
(Fig. 9-74 and Fig. 9-75)
R
Radii breakout cuts, 2-45
Radii generation
chemical milling, 14-89
engine lathe attachment, 8-9 (Fig. 8-9)
planing, 7-47 (Fig. 7-53)
boring tools, 8-85, 8-86 (Table 8-22)
broaches, 7-13 (Fig. 7-10)
cast cobalt-based alloy, 3-15 (Table 3-7)
cemented tungsten carbide, 3-21
ceramic, 3-34
chasers, diehead, 12-58,12-59 (Table 12-28)
cubic boron nitride, 3-47
effective, oblique cutting, 1-13
form tools, 8-41, 8-45 (Fig. 8-59)
hacksaw blades, 6-6 (Fig. 6-4)
hydrodynamic machining, 14-2(Fig. 14-2),
inserts, 8-35
planing tools, 7-44 (Table 7-9)
polycrystalline diamond, 3-43
saw bands,6-19(Fig. 6-16),6-21 (Fig. 6-18)
saw blades, 6-42 (Fig. 6-33)
shaping tools, 7-50 (Fig. 7-60 and Fig. 7-
single-crystal diamond, 3-40
single-point tools, defined, 8-27, 8-28
true vs. effective, 1-6
hacksaw blades, 6-6 (Fig. 6-5)
saw bands, 6-20 (Fig. 6-17)
Ranking test, 1-43
Re-refining
defined, 4-54
methods, 4-55
carbide, 9-111, 9-1 12 (Table 9-38), 9-113
Radii, insert, 8-37
Rake angle
14-3
61), 7-51 (Fig. 7-62)
Raker set
Readouts, 5-33
Reamers (see also Reaming)
(Fig. 9-114)
clearance and blade angles, 9-1 10 (Fig.
combination drill and reamer, 9-113 (Fig.
9-111)
9-113)
defined, 9-107
grinding wheels for, 11-28 (Table 11-8),
hand of cut, 9-111 (Fig. 9-112)
hand of helix, 9-1 11 (Fig. 9-112)
high-speed steel, powdered metal, grades,
3-13 (Table 3-4)
holders and drivers
11-30 (Table 11-10)
float, 9-124 (Fig. 9-128)
requirements, 9-123
types, 9-123, 9-125 (Fig. 9-129)
margins, 9-111, 9-112 (Table 9-37)
terminology, 9-107
types
adjustable, floating, 9-116, 9-118 (Fig.
block, 9-1 19, 9-120 (Fig. 9-121), 9-121
bore reamers, 9-123
chucking, 9-1 15 (Fig. 9-115)
coolant-fed, 9-123
end-cutting, 9-115, 9-117 (Fig. 9-116)
expansion, 9-115 (Table 9-40), 9-1 16,
gunbores, 9-121,9-122 (Fig. 9-124)
hand, 9-115,9-132
illustrated, 9-1 13 (Fig. 9-113)
inserted blade, 9-119(Fig. 9-119), 9-120
(Fig. 9-120)
jobbers, 9-1 15
shell, 9-115,9-117 (Table 9-42)
special, 9-123, 9-124 (Fig. 9-127)
9-118)
(Fig. 9-122)
9-117 (Fig. 9-117)INDEX
Reamers, types (cont.)
structural, 9-119
stub screw-machine, 9-115,9-116(Table
tapered hole, 9-1 18
taper-pin, 9-118
Reaming (see also Reamers)
9-41)
accuracy, 2-2 (Fig. 2-1), 9-109 (Table 9-36),
applications, 9-13 1
bellmouthing, 9-132
chatter, 9-131
cutting fluids, 4-10 (Table 4-2)
defined, 9-107
jig-boring machines, 8-107 (Fig. 8-157)
procedures
9-126 (Table 9-43), 9-132
hand reaming, 9-132
stationary tools, 9-132
reamers, 9-107
speeds and feeds, 9-127
stock removal allowance, 9-107, 9-108
(Table 9-35)
surface finish, 9-132
Swiss-type automatic screw machines,
troubleshooting, 9-133 (Table 9-46)
workholding, 9-125
workpiece design considerations, 9-107,9-
108 (Fig. 9-109)
15-27
Rebuilding/ remanufacturing, machine tool
control retrofitting, 17-4
defined, 17-1
in-house vs. outside, 17-2
justification, 17-1
procedures, 17-2
defined, 1-32
depth of, machining, 1-30 (Table 1-4)
Recessing, attachment for bar and chucking
Reciprocate grinding (see Grinding, cyljnReclaiming
Reconditioning
Recast layer
machines, 15-36 (Fig. 15-31)
drical, and Grinding, surface)
defined, 4-54
methods, 4-54
cutting tool (see Grinding, tool)
machine tool, 17-1
Recrystallization
defined, 1-33
depth of, machining, 1-30 (Table 1-4)
Recycling
cutting fluids, 4-54
lubricants, industrial, 4-54
Redwood system,viscosity measurement, 4-38
Reflectivity, effects in laser cutting, 14-64
Refractories
abrasive cutoff wheels, I 1-122(Table 11-23)
cutting fluids, 4-10 (Table 4-2), 4-13
grinding fluids, 11-46 (Table 11-16)
Regulating wheel types, 11-26 (Table 11-7)
Rehbinder effect, 4-3
Relief angle
boring tools, 8-85, 8-86 (Table 8-22)
ceramic, 3-35 (Table 3-21)
defined, 8-27
planing tools, 7-44 (Table 7-9)
polycrystalline diamond, 3-43
saw blades, 6-42 (Fig. 6-35)
shaping tools, 7-50 (Fig. 7-60 and Fig. 7-
61), 7-51 (Fig. 7-62)
single-point tools,8-29
defined, 4-54
methods, 4-55
cutting fluids
Removal rate (see Material removal rate)
Reprocessing
Reservoir
Reservoir, cutting fluids (cont.)
access, 4-16
capacity, 4- 16
cleaning, 4-27 (Table 4-6)
types, 4-16
industrial lubricants
construction, 4-52
size, 4-53
Residue, cutting fluid, 4-28
Resin bond coated abrasives, 11-42
Resin over glue bond coated abrasives, 11-42
Resinoid bond wheels, defined, 11-16
Resists
photographic, 14-82, 14-84 (Table 14-28),
screen printed, 14-82, 14-84(Table 14-28),
Resolution, 5-32
Resource Conservation and Recovery Act,
Restoration, machine tool (see Rebuilding/
Retaining fixture, 11-61 (Fig. 11-33 and Fig.
Retrofitting, control
case study, 17-14
control system selection, 17-7, 17-8 (Table
defined, 17-1, 17-5
installation, 17-13
interface design, 17-8
justification, 17-5
methods, 17-6
support planning, 17-7
14-90
14-91
cutting fluids, 4-33
remanufacturing machine tool)
11-34), 1 1-62 (Fig. 11-35)
17-2)
Reuse method, lubricant application, 4-51
Reverse flow EDM, 14-45, 14-47 (Fig. 14-46)
Reverse osmosis, 4-26 (see also Filtration and
Reverse polarity EDM, 14-49
Rifling broach, 7-31
Right-angle fixture, 11-63 (Fig. 11-40), 11-64
Rigidity, machine tool, effect on surface finish,
Ring distributor, cutting fluids, 4-14
Ring oiling, 4-53 (Fig. 4-29)
Ring test, grinding wheels, 11-18
Robots and robotics
application guidelines, 16-15
attributes, 16-15
configurations, 16-14 (Fig. 16-13), 16-15
future, 16-22
machine loading/ unloading, 16-20 (Table
work cells, 16-16, 16-17 (Fig. 16-16)
filters)
(Fig. 11-41)
1-22
(Fig. 16-14 and Fig. 16-15)
16-5)
Rock wool, hydrodynamic machining of, 14-8
Roll grinding, 11-70
Rollability
Roller-chain sprocket cutter, 10-25 (Fig. 10-38)
Rolling
(Table 14-3)
defined, 12-128
vs. machinability, 13-30
bar stock, 13-29
fluids, 13-30
gears and splines, 13-26
threads, 12-126
worms, 13-29
Rolling, thread (see Thread rolling and thread
Rotabroach, 9-40 (Fig. 9-23)
Rotary broach, 7-28, 7-32
Rotary diamond wheels, 11-29
Rotary table attachments
rolls)
inclinable, 8-104 (Fig. 8-150), 8-106 (Fig.
milling, 10-22
8-154)
Rotary table, inclinable, 8-104 (Fig. 8-150),
Rotary ultrasonic machining (RUM)
8-106 (Fig. 8-154)
core drilling, 14-1I
drilling, 14-10, 14-12 (Table 14-8 and Fig.
machine tools, 14-12
milling, 14-12
principles, 14-9
threading, 14-12
workpiece materials, 14-10 (Table 14-5)
14-10)
Rotary-cut broach, 7-30 (Fig. 7-32)
Rotary-index machines (see Dial-type
Rotating electrode EDM, 14-55
Rotating fixture, 8-98 (Fig. 8-136)
Roughness (see Surface finish)
Roundness, hole
machines)
boring, 8-79 (Table 8-20), 8-100
symbology, 2-3 (Fig.2-3)
Rubber bond wheelq, defined, 11-16
Rubber, hard
abrasivecutoffwheels, 11-122(Tahle 11-23)
carbide cutting tools, classifications, 3-22
carbide-tipped reaming, 9-114(Table 9-39)
cylindrical grinding wheels, 11-28 (Table
drilling, laser, 14-68 (Table 14-21)
drilling, twist, 9-90 (Table 9-20)
high-speed steel tools, geometry, 8-29
(Table 8-3)
hydrodynamic machining, 14-7(Table 14-
2), 14-8 (Table 14-3), 14-9 (Table 14-4)
polycrystalline diamond tools, 3-43
cylindrical grinding wheels, 11-28 (Table
drilling, laser, 14-68 (Table 14-21)
hydrodynamic machining, 14-7 (Table 14-
2), 14-8 (Table 14-3), 14-9 (Table 14-4)
(Table 3-11)
11-8)
Rubber, soft
11-8)
Ruby laser, 14-63, 14-64(Table 14-19)
Ruby, synthetic, ultrasonic machining of, 14-
RUM (see Rotary ultrasonic machining)
Runout, 2-3 (Fig. 2-3)
11 (Table 14-6)
S
S-N curve
defined, 1-38
4340 steel, surface ground, 1-38 (Fig. 1-59)
boring, 18-13
circular sawing, 6-46
combustible chips, 18-13
cutting fluids, 4-32
drilling, milling, and boring machines,
electrochemical machining, 14-35
expendable tools, 18-8, 18-9 (Fig. 18-5)
fire protection, 18-15
grinding machines, 11-33
grinding wheels, 11-33
guards, types of, 18-3, 18-5 (Table 18-2)
hacksawing, power, 6-1 1
hazard recognition, 18-2
hazard treatment, 18-2
history, 18-1
how people get hurt, 18-2 (Table 18-1)

lasers, 14-70
lubricants, industrial, 4-32
machine guarding, principles, 18-2
machine lockout, 18-8, 18-9 (Fig. 18-6)
maintenance and repair, 18-8
milling, 10-74, 18-12
multiple-spindle automatic bar and chuckSafety
9-106
ing machines, 15-39
1-23INDEX
Safety (cont.)
NC machine tools, 5-11
nonmechanical hazards, 18-8
OSHA impact, 18-1I
personal protection, 18-14
portable air tools, 11-34
safeguarding, 18-3, 18-14
safety aids, 18-5, 18-7 (Table 18-4)
threading, 18-13
training, 18-14
turning, 8-77, 18-11
Sandwich brazing, 8-70 (Fig. 8-100)
Saponification, 4-42
Saw bands (see also Bandsawing)
knife-edge, 6-22, 6-23 (Fig. 6-20)
materials, 6-20
pitch, 6-2 1, 6-22 (Table 6-4)
polishing, 6-22
scallop-edge, 6-22, 6-23 (Fig. 6-20)
selection, 6-19
set, 6-22
terminology, 6-19 (Fig. 6-16)
thickness, 6-21
tooth geometry, 6-19, 6-21 (Fig. 6-18)
wavy-edge, 6-22, 6-23 (Fig. 6-20)
width, 6-21 (Fig. 6-19)
carbide-tipped, 6-41
grinding wheels for sharpening, 11-30
life, 6-45
pitch, 6-43 (Fig. 6-36), 6-44
segmental, 6-40, 6-41 (Fig. 6-32)
solid, 6-40
Saw blades
(Table 11-10)
Sawing, electrochemical, 14-29 (Fig. 14-30)
Sawing, power (see Hacksawing, Bandsawing,
and Circular sawing)
Saybolt system, viscosity measurements, 4-38
Scalloped-edge inserts, 10-30, 10-31 (Fig.
Scheduling, 5-9
Scraping tools, carbide, 3-22 (Table 3-11)
Screening (see Straining)
Screw machines, single-spindle automatic
10-46)
cam-controlled automatics
attachments, 15-21 (Fig. 15-11), 15-22
(Fig. 15-12, Fig. 15-13 and Fig. 15-
cam and tool design, 15-7, 15-8 (Table
15-2), 15-12(Table15-3), 15-13(Table
15-4 and Fig. 15-8), 15-14(Fig. 15-9),
15-15 (Table 15-5), 15-16 (Table 15-
6), 15-18 (Table 15-7), 15-19
14), 15-23
tools, 15-19, 15-20 (Fig. 15-10), 15-21
defined, 15-7
programmable
CNC programming, 15-23
control drum programming, 15-23
toggle switch programming, 15-23
Screw machines, Swiss-type automatic
cam-controlled, 15-24(Fig. 15-15), 15-25
attachments, 15-25
cam layouts, 15-25 (Fig. 15-16)
operating parameters, 15-26(Table 15-
CNC, 15-28(Fig. 15-17 and Fig. 15-18)
defined, 15-23
Screw machining
cutting fluid flow recommendations, 4-14
single-spindle automatic machines, 15-7
slotting attachment for screw machines,
sound levels, typical, 18-25 (Fig. 18-20)
threading, 12-55 (Fig. 12-26), 12-134
8), 15-27 (Table 15-29)
(Table 4-3)
(Fig. 15-7)
15-21 (Fig. 15-11)
Screw threads, Acme
Screw threads, Acme (cont.)
allowances, tolerances, and clearances, 12-
33 (Fig. 12-11)
applications, 12-32
basic dimensions, 12-33, 12-34 (Table
diameter-pitch combinations, 12-33, 12-35
limiting dimensions and tolerances, 12-33,
rollability, 12-128 (Fig. 12-92)
thread form and symbols, 12-32(Fig. 12-10)
12-15)
(Table 12-16)
12-36 (Table 12-17)
Screw threads, metric (see also Threads and
threading)
advantages, 12-41
M profile
applications, 12-42
defined, 12-42
external, limiting dimensions, 12-42,
internal, limiting dimensions, 12-42,
IS0 basic profile, 12-42 (Fig. 12-15)
rounded roots on external threads, 12-
12-45 (Table 12-23)
12-43 (Table 12-22)
42 (Fig. 12-16)
MJ profile
defined, 12-42
inch threads, compared with, 12-42
Screw threads, Unified Inch (see also Threads
and threading)
features, 12-8, 12-11 (Fig. 12-4)
history, 12-8
limits of size, 12-9, 12-12(Table 12-6), 12-
standard sizes, 12-8, 12-10(Table 12-5)
tapping, 12-103
thread classes, 12-8
thread rolling, 12-128,12-129 (Table 12-63)
22 (Fig. 12-5), 12-23 (Fig. 12-6)
Scribing for chemical milling, 14-83
Secondary shear, 1-4, 1-5 (Fig. 1-10)
Selective etching (see Intergranular attack)
Self-excited vibration, 8-77
Semichemical fluids, 4-6, 4-7
Sensor technology, 5-68
Separation, cutting fluids, 4-17 (see also
Clarification and clarity)
Separator, magnetic
cutting fluids, 4-19
grinding fluids, 11-48
Sequence controllers, 5-1
Serrations, broaching, 7-29
Servo control
bandsaws, 6-19
defined, 5-28
EDM machines, 14-54
selection, 5-31
Setting angle, 8-28
Settling
cutting fluids, 4-17 (Fig. 4-3)
electrolytes, 14-27
grinding fluids, 11-48
applications, 14-36
machine tools, 14-36
operating parameters, 14-36
principles, 14-35
Setup, NC, 5-9
Shaped tube electrolytic machining (STEM)
Shaping (see also Shaping tools and shaping,
accuracy, 2-2 (Fig. 2-1)
contouring, 7-53 (Fig. 7-68, Fig. 7-69, and
Fig. 7-70)
cutting fluids, 4-10 (Table 4-2), 7-54
gears and splines, 7-54
machine tools
gear)
horizontal, 7-49 (Fig. 7-58)
vertical, 7-49, 7-50 (Fig. 7-59)
setup, 7-51 (Fig. 7-63 and 7-64)
Shaping (cont.)
speeds and feeds, 7-54
tools
for cast iron, 7-50 (Fig. 7-60)
for chromium alloy steels, 7-51 (Fig.
for steel, 7-50 (Fig. 7-60)
for tool and die steel, 7-50 (Fig. 7-61)
Shaping, ECM, 14-28 (Fig. 14-27 and Fig.
Shaping, gear
7-62)
workholding, 7-52 (Fig. 7-65)
14-28)
gear-shaper method
cutter materials, 13-74
cutter mounting, 13-68, 13-70 (Fig.
cutter specification, 13-75
cutter tooth forms, 13-71 (Fig. 13-80)
cutters, special, 13-71, 13-72 (Table 13-
27), 13-73(Table 13-28)
cutters, standard, 13-68 (Fig. 13-77),
13-69 (Table 13-25)
face clutches, 13-68 (Fig. 13-76)
face gears, 13-67 (Fig. 13-75)
internal gcars, 13-65
machine tools, 13-64 (Fig. 13-66)
molding, generating, 13-63, 13-64(Fig.
sharpening, cutter, 13-74 (Fig. 13-81
and Fig. 13-82)
special applications, 13-66
speed, cutting,13-64
speeds and feeds, 13-67 (Table 13-23),
splines, 13-67 (Fig. 13-74)
workholding, 13-65
principles, 13-63
Shear-Speed process
forms, 13-75 (Fig. 13-83)
machine tools, 13-75
principles, 13-75
workholding, 13-75, 13-76(Fig.13-85)
Shaping tools (see also Shaping and Shaping,
13-78)
13-65)
13-68 (Table 13-24)
gear)
carbide, 3-22 (Table 3-11)
geometry
for cast iron, 7-50 (Fig. 7-60)
for chromium alloys, 7-51 (Fig. 7-62)
for steel, 7-50 (Fig. 7-60)
for tool and die steel, 7-50 (Fig. 7-61)
setup, 7-52 (Fig. 7-66 and Fig. 7-67)
Sharpening, tool (see Grinding, tool)
Shave tools, 8-41, 8-42 (Fig. 8-54), 15-33, 15-
Shear angle, orthogonal cutting, defined, 1-2
Shear, extensive (see Extensive shear)
Shear plane, orthogonal cutting, defined, 1-2
Shear-Speed gear cutting, 13-75
Shear strength
34 (Fig. 15-26)
(Fig. 1-1), 4-2 (Fig. 4-1)
(Fig. 1-l), 4-2 (Fig. 4-1)
mean, orthogonal cutting, 1-11 (Table 1-
rolled threads, 12-127 (Fig. 12-90)
l), 1-14
Shear stress on shear plane vs. feed rate, orthoShellac bond wheels, defined, 11-16
Shielding, laser beams, 14-7I
Shim seat
troubleshooting, 8-77
types, 8-39
Shoulder grinding, 11-68
Shuttle fixture, 8-97, 8-98 (Fig. 8-134)
Shuttle-type(line-index) special machines, 15-
Side cutting edge angle (SCEA)
gonal cutting, 1-12 (Fig. 1-22)
77 (Fig. 15-96)
boring tools, 8-84, 8-85 (Table 8-21)
cast cobalt-based alloys, 3-15 (Table 3-7)
1-24INDEX
Side cutting edge angle (cont.) *’
ceramic, 3-35 (Table 3-21)
defined, 8-27
single-point tools, 8-29
cutters, 10-24
defined, 10-2
speeds and feeds, 10-54 (Table 10-7)
Side milling
Side rake angle (see Rake angle)
Side relief angle (see Relief angle)
Silicate bond wheels, defined, 11-16
Silicon
photo/silk screen resist etchants, 14-84
ultrasonicmachining of, 14-11(Table 14-7)
abrasive for ultrasonic machining, 14-6
applications, 11-15
coated abrasives, 11-41
electron beam machining of, 14-38 (Table
hardness, 14-6
laser cutting, 14-72 (Table 14-23)
laser drilling, 14-68 (Table 14-21)
ultrasonic machining of, 14-11 (Table 14-6
(Table 14-28)
Silicon carbide
14-14)
and Table 14-7)
Silicon-containing compounds
applications, 4-42 (Table 4-10)
comparative ratings, 4-41 (Table 4-9)
greases, 4-46
properties, 4-41
14-84(Table 14-28)
Silver, photo/ silk screen resist etchants for,
Silver tungsten EDM electrodes, 14-52
Simulated production machinability tests, 1-43
Single-crystal diamond cutting tools
advantages, 3-39
applications, 3-39
boring tools, 8-84
cutting fluid compatibility, 4-9
definition, 3-39
forces and power when cutting copper; 1-
19 (Fig. 1-35)
limitations, 3-39
sharpening, 3-40
speeds and feeds, 3-40
surface finish effects, 1-24
tool geometries, 3-39, 3-41 (Fig. 3-19)
turning tools, 8-25
Single-point diamond dressers, grinding
Single-ram broaching machines,7-8
Sinterqd bauxite abrasive applications, 11-15
Sintering
wheels, 1 1-29
ceramic inserts, 3-32
polycrystalline diamond, 3-41
tungsten carbide, 3-18
Six-point locating, 10-46(Fig. 10-71)
Size control, automatic, boring tools, 8-91,
Sizing coat, 11-40, 11-42
Skimmers, tramp oil, 4-17
Skip tooth, 6-19, 6-20 (Fig. 6-17)
Skiving tool, 8-42 (Fig. 8-55)
Slab broach, 7-26
Slot broach, 7-26
Slotting (see also Slotting tools, Shaping, and
Shaping tools)
8-94 (Fig. 8-125)
bandsawing, 6-13
broaching, 7-26, 7-27
cutting fluids, 7-54
electron beam machining, 14-38, 14-39
machine tools, special, 7-49, 7-50 (Fig.
milling, 10-70
milling machine attachment, 10-22
screw machine, 15-26
(Table 14-15)
7-59)
Slotting (cont.)
setup, tool, 7-51 (Fig. 7-63 and Fig. 7-64),
speeds and feeds, 7-54
tool geometry, 7-50 (Fig. 7-60 and Fig.
workholding, 7-52 (Fig. 7-65)
Slotting tools (see also Slotting)
carbide, 3-22 (Table 3-11)
geometry
7-52 (Fig. 7-66 and Fig. 7-67)
7-61)
for cast iron, 7-50 (Fig. 7-60)
for chromium alloys, 7-51 (Fig. 7-62)
for steel, 7-50 (Fig. 7-60)
for tool and die steel, 7-50 (Fig. 7-61)
setup, 7-52 (Fig. 7-66 and Fig. 7-67)
Soap (see Thickeners, grease)
Sodium chlorate electrolyte, 14-25, 14-26
Sodium chloride electrolyte, 14-25, 14-26
Sodium fluoride electrolyte, 14-25
Sodium hydroxide electrolyte, 14-25, 14-26
Sodium nitrate electrolyte, 14-25, 14-26(Table
Sodium nitrite elctrolyte, 14-26 (Table 14-12)
Sodium sulfate electrolyte, 14-26(Table 14-12)
Soft-wired controls, 5-23
Softening, water, 4-26 (Table 4-4) (see also
Dionization, water, and Distillation, water)
Solid mandrels, 11-88 (Fig. 11-80)
Soluble oil
metalcutting, 4-5
special agent, ECM, 14-26
Spade drills and spade drilling
applications, 9-51
blades, 9-51 (Fig. 9-41),9-52(Fig. 9-42and
high-speed steel, powdered metal preforms,
holders, 9-53 (Fig. 9-45), 9-54 (Fig. 9-46,
Spark erosion (see Electrical discharge machinSpark gap
electrical discharge grinding, 14-61, 14-62
electrical discharge machining, convenelectrical discharge wire cutting, 14-59(Fig.
electrochemical discharge grinding, 14-16
Specific cutting pressure, 1-14
Specific power consumption
vs. cutting speed, 1-18
defined, 1-14, 8-64
drilling, 1-19, 1-20 (Fig. 1-36)
milling, 1-19, 1-20 (Fig. 1-36)
planing, 1-19, 1-20 (Fig. 1-36)
spade drilling, 9-85 (Table 9-19)
turning, single-point, 8-64, 8-65 (Table
Speeds and feeds, machining
abrasive cutoff, 11-121
bandsawing, 6-1, 6-12, 6-18, 6-23, 6-25
(Table 6-5)
broaching, 7-3
circular sawing, 6-1, 6-44 (Table 6-9)
counterboring, 9-136, 9-137 (Table 9-47)
drilling, 9-84
electrochemical discharge grinding, 14-17
end milling, 10-56 (Table 10-8)
flycutting, 13-53
friction sawing, 6-13
hacksawing, 6-1, 6-7, 6-8 (Table 6-2)
hobbing, 13-52, 13-55 (Table 13-20)
hydrodynamic machining, 14-3, 14-7
(Table 14-2), 14-8 (Table 14-3), 14-9
(Table 14-4)
(Table 14-12)
(Table 14-12)
(Table 14-12)
14-12)
Fig. 9-43), 9-53 (Fig. 9-44)
3-13
Fig. 9-47, and Fig. 9-48)
ing)
tional, 14-50
14-56)
8-1 7)
Speeds and feeds, machining (cont.)
machining centers, 15-66
milling, 10-54(Table 10-7)
milling vs. power, 10-50
multiple-spindleautomatic bar and chucking machines, 15-37
planing, 1-46 (Table 7-10)
reaming, carbide reamers, 9-127, 9-129
(Table 9-45)
reaming, high-speed steel reamers, 9-127,
9-128 (Table 9-44)
shaping, gear, 13-67 (Table 13-23), 13-68
(Table 13-24)
single-spindle automatic screw machines,
15-8 (Table 15-2)
spotfacing, 9-139
Swiss-type automatic screw machines, 15-
tapping, 12-102 (Table 12-51)
thread chasing, 12-63, 12-64(Table 12-31)
thread grinding, 12-125 (Table 12-60)
thread milling, 12-1 14 (Table 12-56)
threading, single-point, 12-52 (Table 12-
turning
aluminum-oxide-coated carbide tools,
carbide tools, 3-25 (Table 3-12)
cast cobalt-based alloy tools, 3-17
ceramic tools, 3-36, 3-37 (Fig. 3-16)
vs. chip thickness, 1-18
coated carbide tools, 3-30, 3-32, 3-33
(Table 3-18)
coated carbide vs. uncoated carbide
tools, 3-31
cubic boron nitride tools, 3-46 (Table
3-24)
defined, 8-2
vs. depth of cut, 1-47
vs. forces,l-18
vs. metal removal factor, 1-18
polycrystalline diamond tools, 3-43, 3-
vs. power consumption, 1-18
single-crystal diamond tools, 3-40
vs. temperature, 1-45
titanium carbide tools, 3-29(Table3-16)
vs. tool life, 1-46, 3-28 (Fig. 3-12 and
vs. unit power, 1-18, 8-64
26 (Table 15-8), 15-27 (Table 1.5-9)
26), 12-53
3-31
(Table 3-8)
44 (Table 3-23)
Table 3-15), 3-29 (Fig. 3-13)
ultrasonic machining, 14-11 (Table 14-6
ultrasonically assisted turning, 14-14(Table
and Table 14-7)
14-9), 14-15 (Table 14-10)
Spindle, bar bearing, 8-80 (Fig. 8-105)
Splash oiling, 4-53 (Fig. 4-28)
Spline broach, 7-26
Spline rolling (see Gear rolling and spline
Splines and spline manufacturing
broaching, 7-31 (Fig. 7-35), 13-25 (Fig. 13-
diecasting, 13-25
G-TRAC process, 13-62
hobbing, 13-25 (Fig. 13-18), 13-34
involute
applications, 13-19
basic dimensions, 13-17 (Table 13-7)
defined, 13-13
drawings, 13-21, 13-22 (Table 13-11)
history, 13-14
spline design, 13-19
symbols, 13-14
terms, 13-14
types and classes of fit, 13-17, 13-18
(Table 13-8)
variations, dimensional, 13-23(Fig. 13-
rolling)
18), 13-26, 13-33
17), 13-24
1-25INDEX
Splines and spline manufacturing (cont.)
milling, 13-26, 13-30
plastic molding, 13-25
powdered metal, 13-25
rolling, 13-27
shaping, gear, 7-54,13-25 (Fig. 13-18),13-63
stamping and extruding, 13-25
automatic, 9-139 (Fig. 9-147)
defined, 9-134
operation, 9-139 (Fig. 9-146)
speeds and feeds, 9-139
Spotfacing and spotfacers
Square-nose tools, 8-26
Squareness, hole, boring, 8-79 (Table 8-20)
Squeal, tool, 18-19
Stability, cutting fluids, 4-28
Stabler’s Rule, 1-6
Stack cutting, plasma arc machining, 14-75
Staining, cutting fluids, 4-9
Stainless steel (see Steel, stainless)
Standards
cutting fluids
corrosion-ASTM D 130-56,4-28
fire point-ASTM D92-57,4-28
flash point-ASTM D92-57, 4-28
foaming-ASTM D892-58T, 4-28
microbiology- ASTM D3946-80,
stability-ASTM D 1479-57T, 4-28
viscosity-ASTM D88-57,4-28
boring tools, carbide-ANSI B94.5-
1974, 8-85 (Table 8-21)
carbide, cemented-C classification
system, 3-20,3-21 (Table 3-10)
carbide, cemented-IS0 513-1975(E),
3-20,3-22 (Table 3-1I )
carbide chipbreakers for clamp-type
insert holders-ANSI B94.47 Mcarbide seats for clamp-type holderscartridges, precision indexable insertANSI B94.48-1976,8-90,8-92 (Table
cutoff tools, dimensions, straight cutoff blades-ANSI B94.3-1965 (reaffirmed 1972), 8-46
form tool blanks-ANSI B94.32-1954
(reaffirmed 197l), 8-4I
insert dimensional specificationsinsert, heavy-duty, identificationinsert holders, dimensional specifications-ANSI B94.26- 1969(reaffirmed
insert holders, precision, dimensional
specifications-ANSI B94.45-1979,
8-39 (Table 8-10)
insert identification-ANSI B94.4, 8-
35, 8-36 (Table 8-8), 10-30
knurling tools-ANSI B94.6-1981,8-45
single-point brazed tools, carbide
blanks and-ANSI B94.5-1974,8-26,
single-point cutting tools, nomenclasingle-point, roller-turner cutting
solid carbide tips, blanks and semifinished blanks-ANSI B94.1-1977,
ASTM E686-80,4-34
cutting tools
1980,8-39
ANSI B94.46-1973, 8-39
8-24)
ANSI B94.25,8-35, 10-30
ANSI B94.24, 8-35, 10-30
1977), 8-39
8-31
ture-ANSI B94.50-1975, 8-26
tools-ANSI B94.37M-1979, 8-32
8-26
drilling and related processes
drivers, split sleeve, collet-type-ANSI
machine tool safety-ANSI B11.8-
B94.35-1972, 9-68
1974,9-106
Standards, drilling and related processes
(cont.)
reamers-ANS1 B94.2-1977, 9-107, 9-
116 (Table 9-41), 9-1 17 (Table 9-42)
spade drill blades and holders-ANSI
B94.49-1975, 9-51, 9-52 (Fig. 9-42),
9-53 (Fig. 9-45)
taps-ANSI B94.99, 12-81
twist drills, aircraft-NAS 907, 9-38
twist drills, carbide-tipped- ANSI
twist drills, combined drills, and
countersinks-ANSI B94.11-M-1979,
9-14, 9-17, 9-18 (Table 9-2), 9-20
(Table 9-3)
B94.20-1977, 9-16
gears
gear terms-AGMA 116.01, 13-1
geometry-ANSI B6.14-1976, 13-2
hob tolerances, single-thread, coarsepitch- ANSI B94.7-1980, 13-43
(Table 13-18)
spiral bevel gears-AGMA 209.03,13-9
tooth proportions, straight bevel
gears-AGMA 208.03, 13-8
tooth proportions, 20″ involute finepitch spur and helical gears-AGMA
wormgearing, coarse-pitch,cylindricalwormgearing, fine-pitch-AGMA
dropping point-ASTM D-566 and Dextreme pressure-ASTM D-2509, 1P
penetration (hardness)-ASTM D-217,
I P 50, DIN 51 804,4-45,4-46 (Table
rust prevention-ASTM D-1743,4-46
water washout-ASTM D-1264, IP
abrasive grain, size-ANSI B74.12-
coated abrasive grain size-ANSI
machine tool safety-ANSI B11.9-
wheel marking system, bonded, abrasive-ANSI B74.13-1977, 11-19(Fig.
I1-8),11-20 (Fig. 11-9)
wheel safety-ANSI B7.1-1978, 11-33
wheel types and faces-ANSI B74.2-
1974, 11-22(Fig. 11-11and Tablell-
5), 11-23(Fig. 11-12)
lubricants, viscosity-ASTM D 2422
machine control
computer-assisted NC languagesANSI X3.37-1977 and ANSI X3.94-
198X, 5-46, 5-57, 5-60, 5-62 (Fig.
computer output standards, 5-48
data communications-various standoverload protection-NEC, Part C,
PC board construction-JICEL-1-71,
service and installation conditionstape codes-EIA R S 244B, 5-41 (Fig.
tape codes-EIA RS 358B, 5-42 (Fig.
arbors, keyseats, and keys, etc.-ANSI
207.06, 13-8
AGMA 341.02, 13-10
374.04, 13-10
grease
2265, IP 132, DIN51 801,4-46
240, ASTM D-2596, IP 239,4-47
4-14)
215,4-46
grinding
1977, 11-16 (Table 11-2)
B74.18, 11-41
1975, 11-33
(ANSI Z 11.232), 4-39 (Table 4-8)
5-34)
ards, 5-49 (Table 5-17)
Article 430, 5-6
5-33
NEMA ICS 1-108, 5-3
5-22)
5-23)
milling
B5.47-1972, 10-44
Standards, milling (cont.)
machine tools, horizontal and vertical
knee-type and horizontal bed-typemilling cutters, types and sizes-ANSI
B94.19-1977, 10-26 (Table 10-Z), 10-
spindle noses and tool shanks- ANSI
band saw blades-ANSI B94.51-1976,
chucks and chuck jaws, dimensionsANSI B5.8-1972 (reaffirmed 1979),
dimensioning-ANSI Y 14.5-1973,2-3,
laser safety-ANSI Z 136.1, 14-71
machine tool lockout-ANSI 2244.1,
portable air tool safety-ANSI B186.1,
sawing machine safety-ANSI B11.10-
spindle noses-ANSI B5.9-1967 (reaffirmed 1972), 8-53
thread series designations-various
ANSI standards, 12-7, 12-8 (Table
tool life tests, single-point tools-IS0
tool life tests, single-point tools,
materials other than sintered carbide-ANSI B94.34-1946 (reaffirmed
tool life tests, single-point tools, sintered-carbide-ANSI B94.36-1956
(reaffirmed 1971), 8-25
ANSI B5.45-1972, 10-8
28, 10-31
B5.18-1972, 10-8
miscellaneous
6-22
8-53
2-60
18-10
11-34
1974, 6- 1 1, 6-46
12-3)
3685-1977, 1-43
1971), 8-25
sp1ines
involute splines-ANSI B92.1-1970,
involute splines, metric-ANS1 B92.2M
13-14
-1980, 13-14
turning
lathe safety-ANSI B11.6-1975, 8-77
toolroom lathe accuracy- ANSI
B5.16-1952 (reaffirmed 1979), 8-3, 8-
6 (Table 8-2)
Standoff distance
hydrodynamic machining, 14-2(Fig. 14-2),
plasma arc cutting, 14-78
plasma arc turning, 14-76 (Fig. 14-75)
grinders, 11-68
lathes, 8-49, 8-50 (Fig. 8-70), 15-4 (Fig.
roller, 15-33 (Fig. 15-25)
Steatite, ultrasonic machining of, 14-11(Table
Steel, alloy
abrasive cutoff wheels, 11-122(Table 11-23)
bandsawing, 6-25 (Table 6-5)
broaching constant, 7-22 (Table 7-5)
carbide cutting tools
29 (Table 3-16)
28 (Table 3-15)
14-3
Steadyrests
15-3)
14-7)
geometry, 8-30 (Table 8-4)
speeds and feeds, 3-25 (Table 3-12), 3-
tungsten grades vs. titanium grades, 3-
carbide-tipped boring tools, 8-86 (Table
ceramic tools
8-22)
carbide inserts, performance, compared
with, 3-35 (Table 3-20)
geometry, 3-35 (Table 3-21)
speeds and feeds, 3-38 (Fig. 3-1 7)
circular sawing, 6-44 (Table 6-9)
1-26INDEX
Steel, alloy (cont.)
coated-carbide cutting tools
speeds and feeds, 3-32
uncoated inserts, performance compared with, 3-33 (Table 3-18)
counterboring, 9-136, 9-137 (Table 9-47)
cubic boron nitride tools, speeds and feeds,
cut-and-peel mask etchants, 14-86 (Table
cutting fluids, 4-10 (Table 4-2)
drilling
3-46 (Table 3-24)
14-29)
indexable carbide insert, 9-87, 9-92
(Table 9-22)
multiple-lip, external-chip-removal,
high pressure coolant 9-97 (Table
twist, 9-90 (Table 9-20)
end milling, 10-56 (Table 10-8)
face and back-off angles, HSS broaches,
grinding fluids, 11-46 (Table 11-16)
grinding wheels
centerless, 11-26 (Table 11-7)
cylindrical, 11-28 (Table 11-8)
internal, 11-29 (Table 11-9)
surface, 11-25 (Table 11-6)
gundrilling, 9-58 (Table 9-11)
gundrilling, multiple-lip, internal-chipremoval, 9-96 (Table 9-24)
hacksawing, 6-8 (Table 6-2)
high-speed steel tools, geometry, 8-29
(Table 8-3)
hobbing, 13-55 (Table 13-20)
machinability ratings, 1-49 (Table 1-10),
1-52 (Table 1-11)
material removal rate
(Table 6-10)
9-25)
7-18 (Table 7-4)
circular sawing, 6-44 (Table 6-9), 6-45
milling, 10-52(Table 10-5)
milling, 10-35 (Table 10-2), 10-54 (Table
polycrystalline diamond tools, limitations,
reaming, carbide-tipped, 9-114 (Table 9-
reaming, HSS reamers, 9-128 (Table 9-44)
sawing, 6-24
screw machining, 15-8 (Table 15-2)
shaping, gear, 13-67 (Table 13-23)
shaping, tools for, 7-50 (Fig. 7-60)
single-crystal diamond tools, limitations,
surface alterations, 1-28 (Table 1-3)
tapping, 12-102(Table 12-51)
tensile strength, 6-44 (Table 6-9)
thread chasing, 12-58, 12-59(Table 12-28),
12-63, 12-64 (Table 12-31)
thread grinding, 12-125 (Table 12-60)
thread rolling, 12-129 (Table 12-63), 12-
130 (Table 12-64) 12-135(Table 12-66)
threading tools, carbide, cutting speed, 12-
52 (Table 12-26), 12-53
threading tools, high-speed steel,geometry,
12-49, 12-50 (Table 12-24)
tooth pitch, HSS circular saws, 6-43 (Fig.
unit power, single-point turning, 8-65
10-7), 10-69
3-42
39), 9-129 (Table 9-45)
3-39
6-36)
(Table 8-17)
Steel, cast
carbide cutting tools
classifications, 3-22 (Table 3-1I)
speeds and feeds, 3-25 (Table 3-12)
carbide-tipped boring tools, geometry, 8-
cast cobalt-based alloy cutting tools
86 (Table 8-22)
geometry, 3-15 (Table 3-7)
speeds and feeds, 3-17 (Table 3-8)
Steel, cast (cunt.)
ceramic tools, speeds and feeds, 3-38
chasers, rake angle, 12-58, 12-59 (Table
coated-carbide tools, uncoated-carbide,
(Table 3-18)
cubic boron nitride tools, speeds and feeds,
drilling, spade, 9-94 (Table 9-23)
face and back-off angles, HSS broaches,
grinding wheels, internal, 11-29 (Table
machinability ratings, 1-49 (Table 1-10)
material removal rate, milling, 10-52(Table
milling, 10-54(Table 10-7)
planing, 7-46 (Table 7-10)
reaming, carbide-tipped, 9-114 (Table 9-
39), 9-129 (Table 9-45)
tapping, 12-90, 12-91(Table 12-45)
threading tools, high-speed steel, geometry,
12-49, 12-50 (‘Table12-24)
unit power, single-point turning, 8-65
(Table 8-17)
Steel, free-machining
abrasivecutoff wheels, 11-122(Table 11-23)
bandsawing, 6-25 (Table 6-5)
broaching constant, 7-22
carbide cutting tools
geometry, 8-30 (Table 8-4)
speeds and feeds, 3-29 (Table 3-16)
carbide-tipped boring tools, geometry, 8-
ceramic tools
12-28)
performance compared with, 3-33
3-46
7-18 (Table 7-4)
11-9)
10-5)
86 (Table 8-22)
geometries, 3-35 (Table 3-21)
speeds and feeds, 3-38 (Fig. 3-17)
uncoated-carbide, performance compared with, 3-35 (Table 3-20)
circular sawing, 6-44 (Table 6-9)
coated-carbide cutting tools, uncoated
inserts, performance compared with, 3-
33 (Table 3-18)
counterboring, 9-136,9-137 (Table 9-47)
cubic boron nitride tools, speeds and feeds,
cut-and-peel mask etchants, 14-86 (Table
cutting fluids, 4-10 (Table 4-2)
diamond tools, limitations, 3-39, 3-42
drilling
3-46 (Table 3-24)
14-29)
indexable carbide insert, 9-87, 9-92
(Table 9-22)
multiple-lip, external-chip-removal,
high-pressure coolant, 9-97 (Table
spade, 9-85 (Table 9-19), 9-94 (Table
twist, 1-20 (Fig. 1-36)
endmilling, 10-56 (Table 10-8)
face and back-off angles, HSS broaches,
grinding discs for, 11-39 (Table 11-15)
grinding fluid recommendations, 11-46
(Table 11-16)
grinding wheels
9-25)
9-23)
7-18 (Table 7-4)
for centerless, 11-26 (Table 11-7)
for cylindrical, 11-28 (Table 11-8)
for internal, 11-29 (Table 11-9)
for surface, 11-25 (Table 11-6)
gundrilling, multiple-lip, internai-chipremoval, 9-96 (Table 9-24)
hacksawing, 6-8 (Table 6-2)
hardness, optimum for machining, 1-5I
hobbing, 13-55(Table 13-20)
machinability ratings, 1-49 (Table 1-10)
material removal rate
Steel, free-machining, material removal rate
(cunt.)
circular sawing, 6-44 (Table 6-9), 6-45
milling, 10-52(Table 10-5)
milling, 1-20 (Fig. 1-36), 10-35 (Table 10-
planing, 1-20 (Fig. 1-36), 7-46 (Table 7-10)
reaming, carbide-tipped, 9-114 (Table 9-
screw machining, 15-8 (Table 15-2)
shaping, gear, 13-67 (Table 13-23)
shaping, tools for, 7-50 (Fig. 7-60)
surface alterations, 1-28 (Table 1-3)
tapping, 12-102(Table 12-51)
tensile strength, 6-44 (Table 6-9)
thread chasing, 12-58,12-59 (Table 12-28),
12-63, 12-64 (Table 12-31)
thread milling, 12-114 (Table 12-56)
thread rolling, 12-130 (Table 12-64)
threading tools, carbide, single-point, cutting speed, 12-52 (Table 12-26), 12-53
threading tools, high-speed steel, geometry,
12-49, 12-50 (Table 12-24)
tool life exponents, 1-46 (Table 1-6)
tooth pitch, HSS circular saws, 6-43 (Fig.
trepanning, 9-99 (Table 9-26)
turning tools, high-speed steel, geometry,
unit power, single-point turning, 8-65
(Table 6-10)
2), 10-54 (Table 10-7)
39), 9-129 (Table 9-45)
6-36)
8-29 (Table 8-3)
(Table 8-17)
Steel, high-speed
advantages, 3-6
applications, 3-10
bandsawing, 6-25 (Table 6-5)
boring, 8-83
broaches, 7-23 (Table 7-6)
chemical composition, 3-6 (Table 3-1), 3-7
circular saw blades, 6-43 (Fig. 6-36)
classifications, 3-6
cutting fluid compatibility, 4-9
drills, 9-15
drills, small-hole, 9-67
end mills, solid, 10-38
gear shaper cutters, 13-74
grinding wheels
for centerless, 11-26 (Table 11-7)
for cylindrical, 11-28 (Table 11-8)
for offhand, 11-30 (Table 11-10)
for surface, 11-25 (Table 11-6)
for toolroom, 11-30 (Table 11-10)
heat treatment, 3-8 (Table 3-3)
history, 3-4
limitations, 3-7
machinability ratings, 1-49 (Table 1-10)
milling, 10-35(Table 10-2)
molybdenum HSS, 3-6 (Tdble 3-1)
planing tools, 7-44 (Table 7-9)
production methods, 3-5
reaming, carbide-tipped reamers, 9-129
shaping tools for tool and die steels, 7-50
surface finish effects, 1-23
surface treatments, 3-9
taps, 12-86
threading tools, single-point, 12-49, 12-50
(Table 12-24)
tungsten HSS, 3-6 (Table 3-1)
turning tools, 8-25
hobs, 13-39
(Table 9-45)
(Fig. 7-61)
Steel, high-speed, molybdenum (see Steel,
Steel, high-speed, powdered metal
high-speed)
advantages, 3-12
applications, 3-13
broaches, 7-24
1-27INDEX
Steel, high-speed, powdered metal (cont.)
carbide size and distribution, 3-11 (Fig.
3-4), 3-12 (Fig. 3-5)
chemical composition, 3-13 (Table 3-4and
Table 3-5)
drills, 9-15
heat treatment, 3-1I
history, 3-11
manufacturing of, 3-11
taps, 12-86
turning tools, 8-25
chasers, rake angles, 12-58, 12-59 (Table
drilling, twist, 9-90 (Table 9-20)
milling, 10-35 (Table 10-2)
threading tools, high-speed steel,geometry,
Steel, maraging
12-28)
12-49, 12-50 (Table 12-24)
Steel, plain carbon
abrasive cutoff wheels, 11-122(Table11-23)
bandsawing, 6-25 (Table 6-5)
broaching constant, 7-22 (Table 7-5)
carbide cutting tools
classifications, 3-22 (Table 3-11)
geometry, 8-30 (Table 8-4)
speeds and feeds, 3-25 (Table 3-12), 3-
tungsten grades, 3-21 (Table 3-10)
tungsten vs. titanium grades, 3-28
carbide-tipped boring tools, 8-86 (Table
cast cobalt-based alloy cutting tools
29 (Table 3-16)
(Table 3-15)
8-22)
geometry, 3-15 (Table 3-7)
speeds and feeds, 3-17 (Table 3-8)
speeds and feeds, 3-38 (Fig. 3-17)
tool geometries, 3-35 (Table 3-21)
circular sawing, 6-44 (Table 6-9)
coated carbide cutting tools
speeds and feeds, 3-32
uncoated inserts, performance compared with, 3-32, 3-33 (Table 3-18)
counterboring, 9-136,9-137 (Table 9-47)
cubic boron nitride, speeds and feeds, 3-46
diamond tools, limitations, 3-39, 3-42
drilling
indexable-insert, 9-82 (Table 9-18)
multiple-lip, external-chip-removal
high-pressure coolant 9-97 (Table
spade, 9-85 (Table 9-19), 9-94 (Table
twist, 1-20(Fig. 1-36),9-90(Table 9-20)
grinding discs for, 11-39 (Table 11-15)
grinding fluid selection, 11-46(Table 11-16)
grinding wheels
for centerless, 11-26(Table 11-7)
for cylindrical, 11-28 (Table 11-8)
for internal, 11-29 (Table 11-9)
for surface, 11-25(Table 11-6)
ceramics
(Table 3-24)
9-25)
9-23)
gundrilling, 9-58 (Table 9-11)
gundrilling, multiple-lip, internal-chipremoval, 9-96 (Table 9-24)
hacksawing, 6-8’(Table6-2)
high-speed steel tools, geometry, 8-29
(Table 8-3)
honing forheavy stock removal, 11-126
laser cutting, 14-70 (Fig. 14-69)
machinability ratings, 1-49 (Table 1-10)
material removal rate
(Table 6-10)
circular sawing, 6-44 (Table 6-9), 6-45
milling, 10-52(Table 10-5)
milling, 1-20 (Fig. 1-36), 10-35 (Table 10-
planing, 1-20 (Fig. 1-36), 7-46 (Table 7-10)
2), 10-54 (Table 10-7) 10-69
Steel, plain carbon (cont.)
plasma arc cutting, 14-79 (Table 14-26)
reaming, carbide-tipped reamers, 9-129
reaming, HSS reamers, 9- 128(Table 9-44)
shaping, gear, 13-67 (Table 13-23)
shaping, tools for, 7-50 (Fig. 7-60)
surface alterations, 1-28 (Table 1-3)
tapping, 12-102(Table 12-51)
tensile strength, 6-44 (Table 6-9)
thread chasing, 12-58,12-59 (Table 12-28),
12-63, 12-64(Table 12-31)
thread grinding, 12-125(Table 12-60)
thread milling, 12-114 (Table 12-56)
thread rolling, 12-129 (Table 12-63),-12-
130 (Table 12-64), 12-135(Table 12-66)
threading, single-point carbide tools, cutting speeds, 12-52 (Table 12-26), 12-53
tool life exponents, 1-46 (Table 1-6)
trepanning, 9-99 (Table 9-26)
unit power, single-point turning, 8-65
Steel, silicon, photo/ silk screen resist etchants
Steel, stainless
(Table 9-45)
(Table 8-17)
for, 14-84(Table 14-28)
abrasive cutoff wheels, 11-122(Table11-23)
bandsawing, 6-25 (Table 6-5)
carbide cutting tools
29 (Table 3-16)
geometry, 8-30 (Table 8-4)
speeds and feeds, 3-25 (Table 3-12), 3-
carbide-tipped boring tools, geometry, 8-
cast cobalt-based alloy cutting tools
geometry, 3-15 (Table 3-7)
speeds and feeds, 3-17 (Table 3-8)
circular sawing, 6-44 (Table 6-9)
coated carbide inserts, uncoated carbide,
performance, compared with, 3-33(Table
cut-and-peel mask etchants, 14-86 (Table
cutting fluids, 4-10 (Table 4-2)
drilling
indexable-insert, 9-82 (Table 9-18), 9-
87,9-92 (Table 9-22)
multiple-lip, external-chip-removal,
high-pressure coolant 9-97 (Table
spade, 9-94 (Table 9-23;)
twist, 9-102
86 (Table 8-22)
3-18)
14-29)
9-25)
electron beam machining, 14-38(Table 14-
end milling, 10-56 (Table 10-8)
face and back-off angles, HSS broaches,
grinding fluids, 11-44 (Table 11-16)
grinding wheels
centerless, 11-26 (Table 11-7)
cylindrical, 11-28 (Table 11-8)
internal, 11-29 (Table 11-9)
surface, 11-25 (Table 11-6)
gundrilling, 9-58 (Table 9-11)
gundrilling, multiple-lip, internal-chipremoval, 9-96 (Table 9-24)
hacksawing, 6-8 (Table 6-2)
high-speed steel tools, geometry, 8-29
(Table 8-3)
laser drilling, 14-67 (Table 14-20)
machinability ratings, 1-49 (Table 1-10)
material removal rate, circular sawing, 6-
milling, 10-35(Table 10-2), 10-70
photo/ silk screen resist etchants, 14-84
plasma arc cutting, 14-79 (Table 14-26)
plasma atc turning, 14-80 (Table 14-27)
14), 14-39 (Table 14-15)
7-18 (Table 7-4)
45 (Table 6-10)
(Table 14-28)
Steel, stainless (cont.)
reaming, carbide-tipped, 9-1 14 (Table 9-
reaming, H S S reamers, 9-128(Table 9-44),
sawing, 6-24
screw machining, 15-8 (Table 15-2)
shaping, gear, 13-67 (Table 13-23)
surface alterations, 1-28 (Table 1-3)
tapping, 12-90,12-91(Table 12-45), 12-102
tensile strength, 6-44 (Table 6-9)
thread chasing, 12-58,12-59 (Table 12-28),
thread milling, 12-114 (Table 12-56)
thread rolling, 12-1 30 (Table 12-64)
threading tools, carbide, single-point, cutting speed, 12-52 (Table 12-26), 12-53
threading tools, high-speed steel, geometry,
12-49, 12-50 (Table 12-24)
tooth pitch, H S S circular saws, 6-43 (Fig.
trepanning, 9-99 (Table 9-26)
bandsawing, 6-25 (Table 6-5)
carbide cutting tools, speeds and feeds, 3-
carbide-tipped boring tools, geometry, 8-
circular sawing, 6-44 (Table 6-9)
counterboring, 9-136,9-137 (Table 9-47)
cubic boron nitride tools, speedsand feeds,
drilling
multiple-lip, external-chip-removal,
high-pressure coolant 9-97 (Table
spade, 9-94 (Table 9-23)
twist, 1-20(Fig. 1-36),9-15,9-90 (Table
end milling, 10-56(Table 10-8)
face and back-off angles, HSS broaches,
7-18 (Table 7-4)
grindingfluid selection, 11-46(Table 11-16)
grinding wheels, 11-25 (Table 11-6), 11-30
(Table 11-10), 11-39(Table 11-15)
gundrilling, 9-58 (Table 9-11)
hacksawing, 6-8 (Table 6-2)
high-speed steel tools, geometry, 8-29
machinability ratings, 1-49 (Table 1-10}
milling, 1-20(Fig. 1-36), 10-35(Table 10-2)
photo/silk screen resist etchants, 14-84
(Table 14-28)
planing, 1-20 (Fig. 1-36)
properties, 3-4
reaming, carbide-tipped reamers, 9-129
(Table 9-45)
screw machining, 15-8 (Table 15-2)
shaping, gear, 13-67 (Table 13-23)
shaping tools for, 7-50 (Fig. 7-61)
small-hole drilling, 9-67
surface alterations, 1-28 (Table 1-3)
tapping, 12-102(Table 12-51)
tensile strength, 6-44 (Table 6-9)
thread chasing, 12-63, 12-64(Table 12-31)
threading tools, high-speed steel, geometry,
tooth pitch, HSS circular saws, 6-43 (Fig.
turning tools, 8-25
ultrasonic machining of, 14-11(Table 14-6)
S T E M (see Shaped tube electrolytic machinSticks, abrasive, 11-27, 11-29
Stock removal rate (see Material removal rate)
Stone, carbide-cutting tools, classifications, 3-
39), 9-129 (Table 9-45)
9-131
(Table 12-51), 12-106
12-63, 12-64 (Table 12-31)
6-36)
Steel, tool and die
25 (Table 3-12), 3-29 (Table 3-16)
84 (Table 8-22)
3-46 (Table 3-24)
9-25)
9-20)
12-49, 12-50 (Table 12-24)
6-36)
ing)
22 (Table 3-11)
1-28INDEX
Storage
cutting and grinding fluids, 4-23
grinding wheels, 11-33
Straddle broach, 7-27
Straddle milling, defined, 10-2
Straight side-cutting tools, 8-26
Straight-cut NC, 5-34
Straight-flute drills, 9-48
Straight-tooth, circular saw, 6-43 (Fig. 6-36)
Straightness, 2-3 (Fig. 2-3)
Strain and strain rate, orthogonal cutting, 1-3
Straining, cutting fluids, 4-16
Strength, compressive
Strength, fatigue
(Fig. 1-4)
cemented carbide, 3-18, 3-19 (Fig. 3-7)
tungsten carbide, alloyed, 3-19
machining effects, 1-38, 1-40 (Table 1-5)
S-N curve, 4340 steel, surface ground, 1-38
shot peening effects, 1-38
surface traverse grinding, 1-39 (Fig. 1-60)
coated carbide, 3-30
tungsten carbide, titanium grade, 3-19
alloy steel, 6-44 (Table 6-9)
cast iron, 6-44 (Table 6-9)
copper, 14-49 (Table 14-17)
graphite, 14-49 (Table 14-17)
vs. hardness, 1-57
iron, 14-49 (Table 14-17)
low-alloy, high-carbon steels, 6-44 (Table
mild steel, 6-44 (Table 6-9)
optimum for machining of steel, 1-51
stainless steel, 6-44 (Table 6-9)
superalloys, 6-44 (Table 6-9)
tool steel, 6-44 (Table 6-9)
tungsten, 14-49 (Table 14-17)
ceramic inserts, cold-pressed pure, 3-34
composite ceramic inserts, hot-pressed, 3-
titanium carbide, 3-26 (Table 3-14), 3-27
(Fig. 1-59)
Strength, impact
Strength, tensile
6-9)
Strength, traverse rupture
(Table 3-19)
34 (Table 3-19)
(Fig. 3-11)
titanium carbide coated carbide. 3-31
tungsten carbide, alloyed, 3-19,3-21 (Table
tungsten carbide, cemented, 3-19 (Fig. 3-
defined, 1-33
depth below surface, grinding, 11-105(Fig.
depth of, in machining, 1-30 (Table 1-4)
electrical discharge machining of Inconel
718 alloy, 1-36 (Fig. 1-53)
electrochemical discharge grinding, 14-17
electrochemical honing, 14-22
electrochemical machining of Inconel 718
fatigue-endurance effects, 11-104 (Fig.
Hone-Forming, 14-23
milling of AISI 4340 steel, 1-35 (Fig. 1-52)
ultrasonic machining, 14-8
Strip broaching, 7-30 (Fig. 7-31)
Stub Acme screw threads
applications, 12-41
basic dimensions, 12-41 (Table 12-21)
basic thread form, 12-41 (Fig. 12-14)
Subroutines, 5-32
Sulfuric acid electrolyte, 14-25, 14-26 (Table
SumiBoron, 3-45
Sump (see Reservoir)
3-10)
9), 3-27 (Fig. 3-11)
Stress, residual (see also Surface integrity)
11-112)
alloy, 1-36 (Fig. 1-54)
I 1-11 1)
14-12)
Superalloys (iron, nickel, titanium, and
abrasivecutoff wheels, 11-122(Table 11-23)
bandsam,~ig, 6-25 (Table 6-5)
carbide cutting tools
geometry, 8-30 (Table 8-4)
speeds and feeds, 3-25 (Table 3-12)
carbide-tipped boring tools, geometry, 8-
circular sawing, 6-44 (Table 6-9)
cubic boron nitride tools, 3-45
cutting fluids, 4-10 (Table 4-2)
drilling
cobalt-based alloys)
86 (Table 8-22)
indexable carbide insert, 9-87, 9-92
indexable-insert, 9-82 (Table 9-18)
twist, 1-20 (Fig. 1-36), 9-90 (Table 9-
(Table 9-22)
20), 9-102
end milling, 10-56(Table 10-8)
face and back-off angles, HSS broaches,
grinding fluids, 11-46 (Table 11-16)
grinding wheels
centerless, 11-26 (Table 11-7)
cylindrical, I 1-28 (Table 11-8)
internal, 11-29 (Table 11-9)
surface, 11-25 (Table 11-6)
7-18 (Table 7-4)
high-speed steel tools, geometry, 8-29
machinability ratings, 1-49 (Table 1-20)
(Table 8-3)
milling, 1-2O(Fig. i-361, 10-35 (Table ’10-
2). 10-70
photo/silk screen resist etchants, 14-84
planing, 1-20 (Fig. 1-36)
single-crystal diamond tools, limitations,
surface alterations, 1-28 (Table 1-3)
tapping, 12-90,12-91 (Table 12-45), 12-102
tensile strength, 6-44 (Table 6-9)
thread chasing, 12-58,12-59 (Table 12-28),
thread grinding, 12-125 (Table 12-60)
threading tools, H S S , geometry, 12-49,12-
50 (Table 12-24)
threading tools, single-point carbide, cutting speed, 12-52 (Table 12-26), 12-53
trepanning, 9-99 (Table 9-26)
turning, plasma arc, 14-80 (Table 14-27)
unit power, single-point turning, 8-65
(Table 8-17)
(Table 14-28)
3-39
(Table 12-51), 12-106
12-63, 12-64(Table 12-31)
Surface finish
adaptive control, 5-68
bandsawing, 6-12
boring, 1-24, 8-79 (Table 8-20)
broaching, 7-2, 7-4 (Table 7-1)
built-up-edge effects, 1-4 (Fig. 1-8)
chemical machining, 14-82, 14-89
defined, 1-21
vs. dimensional tolerance, 1-21
drilling, 9-4
electrical discharge grinding, 14-62
electrical discharge machining, 14-50
electrical discharge wire cutting, 14-60
electrochemical discharge grinding, 14-17
electrochemical honing, 14-22
electrochemical machining, 14-32
electrochemical turning, 14-35
electron beam machining, 14-39
flaws, 1-21 (Fig. 1-38)
gear hobbing, 13-26
gear shaping, 13-26
hardness, workpiece, effects, 1-23
high-speed grinding, 11-102(Fig. 11-109)
hobbing, 13-36
machinability as a measure of, 1-42
machine tool effects. 1-22
Surface finish (coat.)
vs. machining cost, 1-21, 1-22 (Fig. 1-39)
milling, 1-22, 1-25, 1-26 (Fig. 1-41) 10-7,
no-wear electrical discharge machining,
plasma arc turning, 14-80
reaming, 9-132
roughness, 1-21 (Fig. 1-38)
shaped tube electrolytic machining, 14-36
single-crystal diamond cutting tools, 3-39
spline rolling, 13-27
steel machining, 1-23
symbols, 1-21
thread chasing, 12-127(Table 12-62)
thread grinding, 12-127(Table 12-62)
thread milling, 12-108,12-127(Table 12-62)
thread rolling, 12-127 (Table 12-62)
tool geometry effects, 1-24
turning, 1-22, 1-24, 8-2
ultrasonic machining, 14-7
waviness, 1-21 (Fig. 1-38)
10-74
14-57
Surface finish improver, ECM, 14-25
Surface grinding (see Grinding, surface)
Surface integrity
chemical machining, 1-28(Table 1-3), 1-30
(Table 1-4)
cracks, 1-33
defined, 1-27
distortion in machining, 1-36
drilling, 1-30 (Table 1-4), 9-4
electrical discharge grinding, 14-62
electrical discharge machining, 1-28(Table
1-3), 1-30 (Table 1-4), 14-50
electrical discharge wire cutting, 14-60
electrochemical discharge grinding, 14-17
electrochemical grinding, 1-30 (Table 1-4)
electrochemical honing, 14-22
electrochemical machining, 1-28 (Table I-
3), 1-30 (Table 1-4), 14-32
electron beam machining, 14-39
fatigue strength, 1-38
grinding, 1-30 (Table 1-4)
Hone-Forming, 14-23
intergranular attack, 1-29
laser beam machining, 1-30 (Table 1-4),
14-66 (Fig. 14-65)
microhardness alterations, 1-35
milling, 1-28 (Table 1-3), 1-30 (Table 1-4)
phase transformation, 1-29, 1-32(Fig. 1-45)
plasma arc turning, 14-80
plastic deformation and plastically deformed debris, 1-28, 1-32 (Fig. 1-43 and
Fig. 1-44)
post-processing treatments, 1-35
recast layers, 1-32
recrystallization, 1-33
surface alterations, causes, 1-28
turning, 1-28 (Table 1-3), 1-30 (Table 1-4)
ultrasonic machining, 14-8
Surface roughness (see Surface finish)
Surface smoothing, high-speed steel, 3-9
Surface treatment, HSS
drills, 9-15
general considerations, 3-9
taps, 12-86
Surface-active agents, ECM, 14-25
Surfacing, electrochemical, 14-29(Fig. 14-33)
Swivel vise, 10-23 (Fig. 10-36)
Symmetry, 2-3 (Fig. 2-3), 2-53
Syndite, 3-42
Synthetic fluids
cutting fluids, 4-5
hydraulic oils, 4-56, 4-57 (Table 4-17)
lubricants, industrial
applications, 4-42 (Table 4-10)
comparative ratings, 4-41 (Table 4-9)
types, 4-40
1-29INDEX
T
Tackiness agent, 4-48 (Table 4-16), 4-49
Tank (see Reservoir)
Tantalum
cut-and-peel mask etchant, 14-86 (Table
laser drilling, 14-67 (Table 14-20)
tapping, 12-90, 12-9I (Table 12-45)
14-29)
Tantalum-tungsten, electron beam machining
Tape, NC
Taper generation
of, 14-38 (Table 14-14)
reader/punch, 5-26, 5-48
specifications, 5-41
chemical milling, 14-89
engine lathe, 8-5, 8-9 (Fig. 8-9)
jig grinder, 11-100, 11-101 (Fig. 11-107)
roll grinders, 11-71
turret lathe, 8-I6
Taper, hole boring, 8-79 (Table 8-20), 8-100
Taper turning test, 1-41
Tapping and taps (see also Thread chasing and
thread chasers)
accuracy, 12-68 (Fig. 12-35)
attachments
nonreversing, 12-78 12-79 (Fig. 12-41)
self-reversing, 12-79
collapsing, 12-61
cutting fluids, 4-10 (Table 4-2), 12-102
defined, 12-68
die-head chasing combined with tapping,
12-105, 12-106(Fig. 12-60andFig. 12-61)
difficult-to-machine materials, 12-105
drilling depths, 12-75 (Table 12-38)
forming taps
construction, 12-92 (Fig. 12-48)
defined, 12-90
drill sizes, 12-93 (Table 12-46)
pitch diameter limits, 12-94 (Table
grinding machines, 11-96 (Fig. 11-100)
grinding wheels, tap shanks, 11-28 (Table
heads for tapping, 12-78 (Fig. 12-40)
high-speed steel
grades, 3-10
grinding wheels, 11-30 (Table 11-10)
high-speed steel, powdered metal, grades,
holders
collet-type, 12-97 (Fig. 12-53 and Fig.
extensions, 12-95, 12-96 (Fig. 12-52)
floating, 12-97, 12-98 (Fig. 12-55)
solid holders, 12-95, 12-96 (Fig. 12-51)
split sleeve, 12-95 (Fig. 12-50)
automatics, 12-77 (Fig. 12-38)
characteristics, 12-76 (Fig. 12-37)
leadscrews, 12-77
reversing motors, 12-76
selection, 12-77
specials, 12-77 (Fig. 12-39)
speed changes, 12-76
operations, number of, 12-103
12-47)
11-8)
3-13
12-54)
machine tools
percentage of thread, 12-68, 12-69 (Fig.
12-36)
pipe threads, 12-104, 12-105 (Table 12-52
and Table 12-53)
resharpening, 12-103 (Fig. 12-58 and Fig.
12-59)
screw machining, 15-18
solid adjustable, 12-62
solid taps
(Table 12-45)
geometry, 12-88 (Fig. 12-47), 12-91
grades and tolerances, 12-84
Tapping and taps, solid taps (cont.)
loading or pickup, 12-88
nomenclature, 12-81
number of flutes, 12-88
size recommendations, 12-85 (Table
standard markings, 12-86
tap materials, 12-86
thread symbols, 12-87 (Table 12-41)
types, 12-83 (Fig. 12-46)
12-39), 12-86 (Table 12-40)
special taps, 12-62
special threads, 12-104
speeds and feeds, 12-100, 12-102 (Table
12-51)
tap-drill charts, 12-70(Table 12-35), 12-73
thread elements for variable thread pertorque, 12-99
troubleshooting, 12-107(Table 12-54)
workholding, 12-98
Taylor’s tool life equation
basic, 1-46
extended, 1-47
Tellurium copper EDM electrodes, 14-5I
Temperature
(Table 12-36)
centages, 12-74 (Table 12-37)
ECM electrolyte, 14-27
industrial lubricants
grease, operating, 4-44 (Table 4-11)
index, viscosity, 4-39
vs. viscosity, 4-38
adaptive control, 5-69
boring, jig, 8-108 (Table 8-26)
hydrodynamic machining, 14-3
machinability, as a measure of, 1-42
tool geometry effects, 1-46
tool life effects, 1-45, 4-3
metalcutting
Temperature switches, 5-27
Tempering, high-speed steel, 3-8 (Table 3-3),
Templates
for chemical milling, 14-83
manufacturing of, 14-60
Terminals, computer, 5-46
Terminology (see Nomenclature)
Testing and tests
cutting fluids
grease, 4-45
grinding wheels, 11-18
grinding fluids, acceptability, 11-45
machinability, 1-41
3-9
microbiological, 4-34
physical properties, 4-28
Thermal conductivity (see Conductivity, therThermal cracking (see Cracking)
Thickeners, grease, 4-43, 4-44 (Table 4-11)
Thread chasing and thread chasers
mal)
advantages, 12-54
applications, 12-54, 15-35
attachments
single-point for screw machines, 15-26
universal, 15-36 (Fig. 15-30)
chamfer angle, 12-58 (Fig. 12-31), 12-
60 (Table 12-29), 12-61 (Table 12-30)
rake angles, 12-58, 12-59(Table 12-28)
types, 12-58 (Fig. 12-30)
cutting fluids, 4-10 (Table 4-2)
cutting speeds, 12-63
defined, 12-54
die heads, self-opening
defined, 12-55
rotary, 12-57 (Fig. 12-28)
solid, adjustable, 12-57
specials, 12-57 (Fig. 12-29)
stationary, 12-56 (Fig. 12-27)
chasers, die head
Thread chasing and thread chasers (cont.)
fundamentals, 12-54
power requirements, 12-64, 12-65 (Table
12-32)
resharpening, 11-30 (Table 11-10), 12-64
surface finish, 12-127 (Table 12-62)
tap chasers, 12-63 (Fig. 12-34)
taps, collapsible
defined, 12-61
rotary, 12-62, 12-63 (Fig. 12-33)
stationary, 12-61, 12-63 (Fig. 12-32)
taps, solid adjustable, 12-62
taps, specials, 12-62
threading machines, 12-54, 12-55 (Fig.
troubleshooting, 12-65,12-66 (Table 12-33)
Thread milling
accuracy, 12-108
cutters
12-24)
indexable insert, 12-112 (Fig. 12-72)
maintenance, 12-112
multiple-thread, 12-11I , 12-112 (Table
single-point, 12-I I 1
topping vs. nontopping, 12-1 12
NC/CNC, 12-110, 12-111 (Fig. 12-71)
planetary, 12-110 (Fig. 12-69 and Fig.
production, 12-109 (Fig. 12-68)
universal, 12-109 (Fig. 12-66 and Fig.
speeds and feeds, 12-114 (Table 12-56)
surfacefinish, 12-108,12-127 (Table 12-62)
advantages and limitations, 12-127 (Table
attachments
12-55)
machine tools
12-70)
12-67)
Thread rolling and thread rolls
12-61)
end-feeding, 15-36
end-rolling, 12-1 35 (Fig. 12-104)
side-feeding, 15-35
single-roll (bump), 12-134(Fig. 12-102)
two-roll radial feed, 12-135 (Table
two-roll straddle, 12-135 (Fig. 12-103
blank specifications, 12-135, 12-136 (Fig.
cylindrical-die, 12-132, 12-133(Fig. 12-100)
die life, 12-127, 12-137
die life vs. material hardness, 12-128 (Fig.
flat-die, 12-131(Fig. 12-97and Table 12-65)
overrolling, 12-129 (Fig.12-95)
planetary, 12-134 (Fig, 12-101)
power requirements, 12-129 (Fig. 12-95)
principles, 12-126, 12-127 (Fig. 12-89)
rollability, 12-128, 12-130 (Table 12-64)
surface finish, 12-127 (Table 12-62)
12-66)
and Table 12-66)
12-105)
12-91)
t roub1esho oting, 12-I 37, 12-138’(Table
12-67)
Thread tolerances, API, 12-55
Threading, single-point
depth of cut, 12-53
feed rates, 12-53
machine tools, 12-48
number of passes, 12-53, 12-54 (Table
principles, 12-48
single-point tools
12-27)
brazed carbide, 12-49
helix angles, 12-51, 12-52(Table 12-25)
high-speed steel, geometry, 12-49, 12-
indexable carbide, 12-49 (Fig. 12-19)
50 (Table 12-24)
speeds, 12-52(Table 12-26), 12-53
vee or modified vee, methods of cutting,
12-52, 12-53 (Fig. 12-23)
1-30INDEX
Threads and threading
Acme screw threads, 12-32
Acme screw threads, centralizing, 12-33
API (American Petroleum Institute) tolerattachments, cutting
engine lathes, 8-10, 8-11 (Fig. 8-15)
milling machine, 10-22
Swiss-type automatic screw machines,
turret lathes, 8-16
universal, for bar and chucking
machines, 15-35, 15-36 (Fig. 15-30)
ances, 12-55
15-26
broaching, 7-29
buttress inch screw threads, 12-41
chasing, 12-54
Class 5 interference-fit threads, 12-41
cutting fluids, 4-10 (Table 4-2)
dies, external threading, 12-107
grinding, 12-114
hose coupling screw threads, 12-41
internal threading, solid taps, 12-68
metric screw threads, 12-41
microscopic objective threads, 12-41
milling, 10-70, 12-108
nomenclature, 12-1
nomenclature
dimensions of screw threads, 12-4
geometrical elements of screw threads,
size and fit of mechanical part, 12-2
types of screw threads, 12-1
pipe and pipe thread symbols, 12-4 (Fig.
pipe threads
American National Standard, 12-22
American National Standard Taper,
Dryseal, 12-27
internal straight threads’ in pipe couplings, 12-23
mechanical straight, 12-27
12-2
12-2), 12-7 (Table 12-2)
12-22
rolling, 12-126
rotary ultrasonic, 14-12
safety, 18-14
screw thread symbols, 12-4(Fig. 12-3), 12-
6 (Table 12-1)
single-point, 12-48
solid taps, 12-81
Stub Acme screw threads, 12-41
surface finish, 12-127(Table 12-62)
thread seriesdesignations, 12-7,124 (Table
Unified inch screw threads, 12-8
Unified miniature screw threads, 12-41
12-3), 12-87 (Table 12-41)
Threshhold force, 11-13
Thrust (see Forces, cutting)
Tin, photo/silk screen resist etchants for, 14-
Titanium and alloys (see also Superalloys)
84 (Table 14-28)
abrasive cutoff wheels, 11-122(Table 11-23)
bandsawing, 6-25 (Table 6-5)
carbide tools, geometry, 8-30 (Table 8-4)
carbide-tipped boring tools, geometry, 8-
chasers, rake angles, 12-58, 12-59 (Table
cut-and-peel mask etchants, 14-86 (Table
cutting fluids, 4-10 (Table 4-2)
drilling, spade, 9-94 (Table 9-23)
drilling, twist, 9-90 (Table 9-20), 9-103
electron beam machining, 14-40 (Fig.
end milling, 10-56 (Table 10-8)
face and back-off angles, HSS broaches,
grinding fluids, 11-46 (Table 11-14)
86 (Table 8-22)
12-28)
14-29)
14-39)
7-18 (Table 7-4)
Titanium and alloys (cont.)
grinding wheels
centerless, 11-26 (Table 11-7)
cylindrical, 11-28(Table 11-8)
internal, I 1-29 (Table 11-9)
surface, 11-25 (Table 11-6)
indexable insert drilling, 9-82 (Table 9-8),
machinability ratings, 1-49 (Table 1-10)
milling, 10-35 (Table 10-2), 10-70
photo/ silk screen resist etchants, 14-84
reaming, HSS reamers, 9-128 (Table 9-44)
surface alterations, 1-28 (Table 1-3)
tapping, 12-90,12-9 1 (Table 12-45), 12-102
(Table 12-51), 12-106
thread rolling, 12-130 (Table 12-64)
threading, single-point carbide tools, cutting speed, 12-52 (Table 12-26), 12-53
threading tools, high-speed steel, geometry,
12-49, 12-50 (Table 12-24)
Titanium carbonitride coating for carbide,
Titanium nitride coating for carbide, propTolerance control
conversion, geometric characteristics to
cost vs. tolerance, 2-1
dimensioning, 2-3 (Fig. 2-3)
geometric characteristics, 2-3 (Fig. 2-3)
NC machining, impact on, 2-4
stackup, principles, 2-2, 2-4 (Fig. 2-4)
tolerance charts and charting
9-87, 9-92 (Table 9-22)
(Table 14-28)
3-3I
erties, 3-31 (Table 3-17)
“mean+ tol,” 2-3 (Fig. 2-3)
angular cuts, 2-22
construction, 2-9
defined, 2-5
do’s and dont’s, 2-57, 2-58 (Fig. 2-24)
elements, 2-5, 2-7 (Fig. 2-6)
fundamentals, 2-3
geometric tolerances, 2-52
heat treatment, 2-49
normal curve process capability, 2-9,
plated surfaces,2-52
radii breakout cuts, 2-45
symbols used, 2-9, 2-11 (Fig. 2-9)
workpiece sketch, 2-5, 2-6 (Fig. 2-5),
tolerance specification, 2-1, 2-2 (Fig. 2-2)
trends, 2-4
Tool and cutter grinders, 11-92, 11-93 (Fig.
Tool angles (see Tool geometry)
Tool compensation (see Size control, autoTool failure
2- 10 (Fig. 2-8)
2-8 (Fig. 2-7)
11-92)
matic)
causes, 1-44
drills, 9-96
milling, 10-72
turning tools, 8-76
boring tools, 8-84, 8-86 (Table 8-22)
broaches, 7-13
carbide grades, 3-21
cast cobalt-based alloys, 3-15 (Table 3-7)
ceramic inserts, 3-34, 3-35 (Table 3-21),
3-36 (Fig. 3-14)
cubic boron nitride, 3-47
drills, twist, 9-15 (Fig. 9-15), 9-40
electrochemical machining, 14-33
end mills
indexable-insert, 10-39 (Fig. 10-61)
solid, 10-38, 10-39 (Fig. 10-62)
circular, 8-43
flat, 8-41
Tool geometry
form tools
gundrills, external-chip-removal, 9-56 (Fig.
9-50), 9-60 (Fig. 9-52)
Tool geometry (cont.)
gundrills, internal-chip-removal, 9-57, 9-
hacksaw blades, 6-6 (Fig. 6-4)
high-speed steel, 8-29 (Table 8-3)
indexable-insert drills, 9-50 (Fig. 9-40)
inserts, indexable, 8-35
milling cutters
62 (Fig. 9-59), 9-103 (Fig. 9-108)
hobs, 13-39, 13-60, 13-62
indexable-insert, 10-29(Fig. 10-42),10-
32 (Fig. 10-48), 10-33
geometry vs. power, 10-50
solid, 10-28(Fig. 10-39,Fig. 10-40,and
Fig. 10-41)
planing tools, 7-44 (Table 7-9)
polycrystalline diamond, 3-43,3-44 (Table
reamers, 9-109 (Fig. 9-110), 9-1 10, 9-114
saw bands, 6-19 (Fig. 6-16),6-21 (Fig. 6-18)
saw blades, 6-42 (Fig. 6-33, Fig. 6-34, and
shaping tools, 7-50 (Fig. 7-60 and Fig. 7-
single-crystaldiamond,3-39,3-41 (Fig.3-19)
single-point tools
3-23)
(Table 9-39)
Fig. 6-35)
61), 7-51 (Fig. 7-62)
affects on unit power, 8-64, 8-66
nomenclature, 8-26
threading, high-speed steel, 12-49, 12-
50 (Table 12-24)
tool angles, 8-27
working angles, 8-28
slotting tools, 7-50 (Fig. 7-60and Fig. 7-61)
spade drill blades, 9-52,9-102 (Table 9-31)
surface finish affects upon, 1-23, 1-24
taps, solid, 12-88(Fig. 12-47), 12-91(Table
temperature effects, 1-46
titanium carbide, 3-29
trepanning tools, 9-65 (Fig. 9-67)
12-45)
Tool grinding (see Grinding, tool)
Tool life and tool wear
adaptive control, 5-69
bandsawing, 6-25 (Table 6-5)
causes of tool wear, 1-44
circular sawing, 6-45
cutting speed effects, 1-46 (Fig. 1-62)
dimensions of cut effects, 1-47
electrical discharge machining, 14-50
electrical discharge wire cutting, 14-60
electrochemical machining, 14-34
engagement of tool, effects of, 1-48
hobs, 13-48 (Fig. 13-50)
milling
built-up edges, 10-72
chip welding, 10-72
chipping, 10-72
cratering, 10-72
edge deformation, 10-73
edge notching, 10-73
flank wear, 10-72(Fig. 10-93)
insert fracture, 10-74
residual stress vs. tool wear, 1-35 (Fig.
thermal cracking, 10-73
observing tool failure, 1-44
specification, 1-44
temperature effects, 1-45
tests, machinability, 1-41
thread rolling, die life vs. material hardness,
thread rolling dies, 12-137
titanium carbide vs. tungsten carbide, 3-
tool geometry effects, 1-47
triple-coated carbide inserts, 3-32
ultrasonic machining, 14-8, 14-11 (Table
1-52)
12-128 (Fig. 12-91)
27, 3-29 (Fig. 3-13)
14-6 and Table 14-7)
1-31INDEX
Tool life and tool wear (cont.)
14-15 (Table 14-10)
ultrasonically assisted machining, 14-13,
Tool material (see Cutting tool material)
Tool retraction, boring, 8-91,8-94 (Fig. 8-124)
Tool sharpening (see Grinding, tool)
Tool wear (see Tool life and tool wear)
Toolchangers
horizontal boring machines, 15-44
machining centers, 15-67, 15-68 (Fig. 15-
81,Fig. 15-82 and Fig. 15-83)
NC/CNC lathes, 8-21
vertical boring machines, 15-59,15-60 (Fig.
boring, 8-87
boring, vertical boring machines and turret
lathes, 15-58(Fig. 15-63), 15-59(Fig. 15-
64,Fig. 15-65 and Fig. 15-66)
drilling, 9-67
horizontal boring machines, 15-45 (Fig.
15-40 and Fig. 15-41), 15-46 (Fig. 15-42
and Fig. 15-43), 15-47 (Fig. 15-44 and
Fig. 15-45), 15-48 (Fig. 15-46 and Fig.
15-47),15-49 (Fig. 15-48and Fig. 15-49)
machining centers, I 5-69, 15-70(Fig. 15-84
and Fig. 15-85)
multiple-spindle automatic bar and chucking machines, 15-33, 15-34 (Fig. 15-26
and Fig. 15-27)
reaming, 9-123
single-spindle automatic lathes, 15-5
single-spindle automatic screw machines,
15-19, 15-20 (Fig. 15-10)
threading, 12-49 (Fig. 12-19)
turning, 8-39
15-67)
Toolholders
Tooling cost
NC, 5-10
NC vs. conventional, 5-16, 5-17 (Fig. 5-2)
Toolmaker’s vise, 10-23 (Fig. 10-36)
Toolroom lathe, 8-3
Top jaws, 8-57,8-58 (Table 8-15),8-59 (Table
Topping inserts, defined, 12-5I (Fig. 12-20)
Torch brazing, tipped tools, 8-70
Torque
drilling, spade, 9-81, 9-85 (Table 9-19)
drilling, twist, 9-44 (Fig. 9-31), 9-79
multiple-lip, high-pressure coolant drills,
tapping, 12-99 (Fig. 12-56 and Fig. 12-57)
Toughness (seealso strength, Traverse rupture)
coated carbide, 3-30
high-speed steel, 3-7 (Table 3-2)
high-speed steel, powdered metal, 3-12
tungsten carbide, cemented, 3-19 (Fig. 3-9)
Toxic Substances Control Act, 4-33
Tracing
engine lathes, 8-11, 8-12 (Fig. 8-16)
tracer lathes, 8-13
.
8-16)
9-88 (Fig. 9-99)
Tramp oil skimmers (see Skimmers,tramp oil)
Transfer machines
advantages and applications, 15-81
controls, 15-87
flexible, 16-17, 16-18 (Fig. 16-17)
in-line transfer methods, 15-82, 15-83(Fig.
15-105), 15-84 (Fig. 15-106 and Fig.
machining units, 15-85(Fig. 15-108),15-86
(Fig. 15-109 and Fig. 15-110)
maintaining efficiency, 15-87
rotary, 15-81 (Fig. 15-104)
safety, 18-14
workpiece gaging, 15-87
1.5-107)
Traveling wire EDM (see Electrical discharge
Traverse rupture strength (see Strength,
wire cutting)
traverse rupture)
Traverse speed, grinding, 11-68
Trepanning and trepanning tools
cutting fluids
fluid flow recommendations, 4-14
pressure, 9-99 (Fig. 9-103)
selection, 4-10 (Table 4-2)
(Table 4-3)
machine tools, 9-11
speeds and feeds, 9-99 (Table 9-26)
Trepanning, e1ect rochemica1, 14-29 (Fig.
Triple-chip tooth, 6-42 (Fig. 6-33)
Troubleshooting
14-32)
abrasive belt cutoff, 11-124 (Fig. 11-117)
boring, 8-89
broaching, 7-36 (Fig. 7-39), 7-37 (Table
ceramics, 3-38 (Table 3-22)
circular sawing, 6-43 (Table 6-8)
drilling chatter, 9-102
drilling, twist, 9-104 (Table 9-32)
grinding, 11-109
gundrilling, 9-106 (Table 9-34)
hacksawing, 6-1I (Table 6-3)
indexable-insert drilling, 9-105(Table9-33)
milling, 10-74, 10-75 (Table 10-13)
multiple-spindle automatic bar and chucking machines, 15-39 (Table 15-10)
plasma arc cutting, 14-77 (Fig. 14-76)
reaming, 9-133 (Table 9-46)
tapping, 12-107
thread chasing, 12-65, 12-66(Table 12-33)
thread grinding, 12-I26
thread rolling, 12-137,12-138 (Table 12-67)
tungsten carbide, cemented, 3-26 (Table
turning, 8-76
7-8)
3-13)
True rake angle, single-point tools, defined,
True-solution fluids, 4-6
Trueing, grinding wheel, defined, 11-27 (see
Trunnion machines, 15-77, 15-78 (Fig. 1547)
Tune-up, machine tool, 17-1
Tungsten
abrasivecutoffwheels, 11-122(Table11-23)
boiling point, 14-49 (Table 14-17)
cut-and-peel mask etchants, 14-86 (Table
elasticity, modulus of, 14-49(Table 14-17)
electrical conductivity, 14-49(Table 14-17)
electron beam machining, 14-38(Table 14-
14), 14-39 (Table 14-15), 14-40 (Fig.
grinding wheels
8-28
also Dressing, grinding wheel)
14-29)
14-39)
centerless, 11-26 (Table 11-7)
cylindrical, 11-28 (Table 11-8)
surface, 11-25 (Table 11-6)
heat to vaporize, 14-49 (Table 14-17)
laser drilling, 14-67 (Table 14-20)
machinability ratings, 1-49 (Table 1-10}
melting point, 14-49 (Table 14-17)
surface alterations, 1-28 (Table 1-3)
tensile strength, 14-49 (Table 14-17)
thermal conductivity, 14-49 (Table 14-17)
wire, EDM electrodes, 14-52
Tungsten carbide (see Carbide, tungsten,
Tungsten high-speed steel (see Steel, highTunnel broaching machines, 7-10 (Fig. 7-7)
Turning (see also Turning tools)
cemented)
speed)
accuracy, 2-2 (Fig. 2-1), 8-2
applications
bar work, 8-73, 8-74 (Fig. 8-103)
chucking work, 8-73 (Fig. 8-102)
multiple operations, 8-72 (Fig. 8-101)
Turning, applications (cont.)
multiple-spindle automatic bar and
NC lathe, 8-74
production, 8-72
single-spindle automatic lathes, 15-3
single-spindle automatic screw machturret lathe, 8-72
chip thickness, undeformed, 8-64, 8-66
(Fig. 8-96)
cuttability tests, 1-43
cutting fluids
chucking machines, 15-33
ines, 15-19
flow recommendations, 4-14 (Table4-3)
nozzle size and orientation, 4-15
selection, 4-I0 (Table 4-2), 8-68
cutting forces, measurement, 1-17, 1-18
electromechanical, 14-16
fundamentals, 8-1
high-speed, 8-75
hot machining, 8-75 (Fig. 8-104)
inclination angle, 1-7
with indexable-insert drills, 9-48,9-49 (Fig.
lathe operation, 8-1, 8-2 (Fig. 8-1)
lathe selection, 8-2
lathes, contouring
(Fig. 1-34)
9-38)
engine lathe tracing attachment, 8-11,
tracer lathes, automatic, 8-13
bench, 8-3
8-12 (Fig. 8-16)
lathe, engine
boring attachment, 8-10, 8-11 (Fig.
8-14]
centerless bar-turning, 8-4
drilling attachment, 8-10
gap, 8-3, 8-8 (Fig, 8-5)
grinding attachment, 8-9, 8-10 (Fig.
hollow-spindle, 8-4, 8-8 (Fig. 8-6)
manufacturing, 8-3, 8-8 (Fig. 8-4)
milling attachment, 8-9,S-lO (Fig.8-11)
radius generation, 8-9, (Fig. 8-10)
regular, 8-3
right-angle, 8-4, 8-9 (Fig. 8-7)
sawing attachment, 8-9, 8-10 (Fig.
taper turning, 8-5, 8-9 (Fig. 8-9)
thread cutting attachment, 8-10, 8-11
(Fig. 8-15)
thread rolling attachments, 12-134
toolroom, 8-3
tracing attachment, 8-1I , 8-12 (Fig.
turret attachment, 8-9,8-10 (Fig. 8-13)
accuracy, 8-20
advantages, 8-17
center-type (shaft-type), 8-18
chucking-type, 8-18, 8-19 (Fig. 8-27)
construction, 8-19
control systems, 8-22
limitations, 8-17
options, 8-22
selection, 8-17, 8-19
toolchangers, automatic, 8-21, 8-23
(Fig. 8-33)
turrets, 8-21 (Fig. 8-30and Fig. 8-31)
universal (combination), 8-18, 8-19
(Fig. 8-27)
8-12)
8-1I)
8-16)
lathes, NC/ CNC
planning guidelines, 8-71 (Table 8-19)
plasma arc, 14-76 (Fig. 14-75)
power requirements, 8-64,8-65 (Table8-17)
safety, 8-77
sound levels, typical, 18-25 (Fig. 18-20)
speeds and feeds, 8-67,8-68 (Fig. 8-98and
Fig. 8-99)
1-32INDEX
Turning (cont.)
surface finish, 1-24, 8-2, 8-67 (Fig. 8-97)
surface integrity
depth of alterations, 1-30 (Table 1-4)
types of alterations, 1-28 (Table 1-3)
tools, 8-24
troubleshooting, 8-76
turret lathes, horizontal
automatic, 8-I6
hand, 8-14, 8-15 (Fig. 8-21)
ram-type, 8-15, 8-16 (Fig. 8-22), 8-17
saddle-type, 8-15, 8-16 (Fig. 8-23)
tauer attachments. 8-16
(Fig. 8-24)
thkading attachments, 8-16, 12-55,
12-134
ultraprecision, 8-75
ultrasonic, 14-13 (Fig. 14-13)
workholding, 18-47, 18-11
Turning tools (see also Turning)
brazing of tipped tools, 8-70
burnishing, 8-46
carbide, titanium
applications, 8-25
vs. carbide, tungsten, 3-28 (Table 3-15)
geometry, 3-29
grades, 3-26 (Table 3-14)
speeds and feeds, 3-29 (Table 3-16)
applications, 8-25
vs. carbide, titanium, 3-28 (Table 3-15)
geometry, 3-21
grades, 3-21, 3-22 (Table 3-1 I )
speeds and feeds, 3-25 (Table 3-12)
cast cobalt-based alloys
applications, 8-25
geometry, 3-15 (Table 3-7)
speeds and feeds, 3-17 (Table 3-8)
applications, 8-25
geometry, 3-34,3-35 (Table 3-21),.3-36
speeds and feeds, 3-36,3-37 (Fig. 3-16)
performance vs. uncoated carbide, 3-33
speeds and feeds, 3-30, 3-33 (Table 3-
applications, 8-25
geometry, 3-47
performance, 3-47 (Table 3-25)
speeds and feeds, 3-46 (Table 3-24), 3-
types, 3-45
cutoff, 8-46 (Fig. 8-61), 8-47 (Fig. 8-62 and
form tools
carbide, tungsten
ceramics
(Fig. 3-14)
chip control, 8-30
coated carbide
(Table 3-18)
18), 3-32
cubic boron nitride
47 (Table 3-25)
Fig. 8-63)
depth of cut calculations, flat form
dovetail, 8-41
end form, 8-41
manufacturing of, 14-59
radius of the inner cut calculation,
circular form tools, 8-43
shave, 8-41, 8-42 (Fig. 8-54)
skiving, 8-42
high-speed steel
applications, 8-25, 8-26
geometry 8-29 (Table 8-3)
grades, 3-10
high-speed steel, powdered metal
applications, 8-25
grades, 3-13
holders, indexable-insert
identification system, 8-39 (Table 8-10)
styles, 8-40 (Fig. 8-51)
tools, 8-42, 8-43 (Fig. 8-56)
Turning tools (cont.)
indexable inserts
automatic changing, 8-40 (Fig. 8-52)
geometry, 8-35, 8-36 (Table 8-8)
holders, 8-39 (Table 8-10)
identification system, 8-36 (Table 8-8)
retention of, 18-12
selection, 8-35
knee turners, 15-33
knurling
circular pitch, 8-46 (Table 8-14)
defined, 8-45
nomenclature, 8-26
polycrystalline diamond
applications, 3-43, 8-25
geometry, 3-43, 3-44 (Table 3-23)
performance vs. carbide and singlecrystal diamond, 3-44 (Table 3-23)
speeds and feeds, 3-44 (Table 3-23)
preset tooling, 8-47
qualified tooling, 8-47
roller turners, 15-33
screw machining, 15-19, 15-20(Fig. 15-10)
selection, 8-64
sharpening, 8-69
single-point, solid, 8-25
single-crystal diamond
single-point, brazed-tip
applications, 3-39, 8-25
geometries, 3-39, 3-41 (Fig. 3-19)
carbide blanks, 8-31, 8-33 (Table 8-7)
defined, 8-26
holders, 8-32, 8-35 (Fig. 8-46 and Fig.
8-47)
styles, 8-26
tool angles, 8-27 (Fig. 8-40)
troubleshooting, 8-76
working angles, 8-28
horiiontal, 8-14, 8-15 (Fzg. 8-21)
Turret lathes
automatic, 8-16
ram-type, 8-15, 8-16 (Fig. 8-22), 8-17
(Fig. 8-24)
saddle-type, 8-16 (Fig. 8-23)
vertical (VTL’s)
applications, 15-61 (Fig. 15-69)
capacities, 15-55, 15-56 (Table 15-12),
construction, 15-54 (Fig. 15-59), 15-55
controls, 15-55
defined, 15-53, 15-54 (Fig. 15-58)
machine loading, 15-57, 15-58 (Fig.
tooling, 15-58 (Fig. 15-63), 15-59 (Fig.
workholding, 15-60
15-57 (Table 15-13)
(Fig. 15-60 and Fig. 15-61)
15-62)
15-64 and Fig. 15-65)
Twist drills, 9-14
Two-way broaching machines, 7-10
U
UAM (see Ultrasonically assisted machining)
Ultraprecision machining, 8-75
Ultrasonic machining (USM)
abrasives, 14-6
forces on the workpiece, 14-8
frequency, 14-7
machine tools, 14-9
principles, 14-5, 14-10 (Fig. 14-9)
vibration amplitude, 14-8
wear ratio, 14-8, 14-11 (Table 14-7)
workpiece materials, 14-6, 14-10 (Table
Ultrasonically assisted machining (UAM)
applications, 14-13
drilling, 14-15
tools, 14-6
14-5)
Ultrasonically assisted machining (cont.)
gundrilling, 14-13, 14-15 (Fig. 14-15)
lathe turning, 14-13 (Fig. 14-13), 14-14
material removal rate, 14-14 (Fig. 14-14
principles, 14-12, 14-13 (Fig. 14-13)
Undeformed chip thickness (see Chip thickUndercut error, NC, 5-43 (Fig. 5-25)
Undercut, photochemical machining, 14-91
Unit power consumption (see Specific power
Untempered martensite, 1-29, 1-32(Fig. 1-45),
Up milling
(Table 14-9)
and Table 14-9)
ness, undeformed)
consumption)
1-35
applications, 10-5
defined, 10-3, 10-4 (Fig. 10-1)
abrasivecutoffwheels, 11-122(7uble 11-23)
laser drilling, 14-67 (Table 14-20)
tungsten carbide, alloyed, machining with,
Updating, machine tool, 17-1
Uranium
3-20
Used oil, defined, 4-53
USM (see Ultrasonic machining)
Utilization
average, 16-2
NC equipment, 5-10
V
~
Vacuum chuck, turning, 8-62
Vacuum filters
cutting fluids, 4-21, 4-22 (Fig. 4-8)
grinding fluids, 11-48
VBM’s (see Boring machines, vertical)
Vertical boring machines (VBM’s) (see Boring
machines, vertical)
Vertical turret lathes (VTL’s) (see Turret lathes,
vertical)
Vibration
amplitude, ultrasonic machining, 14-8
turning, 8-76
Vibration test, grinding wheels, 11-18
Viscosity
cutting fluid tests, 4-28
lubricants, industrial
classification, 4-39 (Table 4-8)
defined, 4-38
elastohydrodynamic, 4-36
index, 4-39
index improvers, 4-48 (Table 4-16)
vs. temperature, 4-38
Vises, workholding
hacksawing, 6-6, 6-7 (Fig. 6-6)
milling, 10-23 (Fig. 10-36)
precision, grinding, I 1-61
vise-jaw fixture, 11-62, 11-63 (Fig. 11-38
and Fig. 11-39)
Vitrified bond wheels, defined, 11-16
Voice recognition, 5-46
VTL’s (see Turret lathes, vertical)
W
Waspaloy (see Superalloys)
Waste oil, defined, 4-53
Water resistance, grease, 4-44 (Table 4-11)
Water swirl injection, 14-75 (Fig. 14-72)
Water treatment, cutting fluids, 4-25
Water washout (see Water resistance, grease)
Waviness, surface (see also Surface finish)
defined, 1-21 (Fig. 1-38)
face milling, 1-26
peripheral milling, 1-27
1-33INDEX
Wavy set
hacksaw blades, 6-6 (Fig. 6-5)
saw bands, 6-20 (Fig. 6-17)
Way-type boring machine, 8-8 1, 8-82 (Fig.
Wear and antiwear agents
8-110)
broaching tools, 7-13
drills, 9-93
industrial lubricants, 4-47 (Table 4-15)
reamers, 9-I33 (Table 9-46)
electrochemical discharge grinding, 14-17
ultrasonic machining, 14-8, 14-11 (Table
coated carbide, 3-30, 3-3 I
cubic boron nitride cutting tools, 3-45
high-speed steel, 3-7 (Table 3-2)
grinder, 11-94, 11-95 (Fig. 11-96)
procedure, 9-44 (Fig. 9-30 and Fig. 9-32),
specification, 9-43 (Table 9-9)
Wear ratio
14-7)
Wear resistance
Web thinning
9-96
Wedge cutting, ECM, 14-28 (Fig. 14-29)
Weirs, multiple, 11-48
Wetting agents, cutting fluids, 4-6
Wheel wear parameter, 11-14
Wheel/work characteristic chart, 11-13 (Fig.
11-6)
Wheels, abrasive cutoff
dry vs. wet cutting, 11-121
feed, 11-121
horsepower vs. wheel grade, 11-12
speed, 11-121
troubleshooting, 11-124(Fig. 11-1
types, 11-122 (Table 11-23)
Wheels, grinding
abrasive types, 11- 15
air deflector nozzle, 11-47
balance, 11-25, 11-31 (Fig. 11-13)
bond, 11-16
7)
broach sharpening, 7-36
for cast cobalt-based alloys, 3-18 (Table
centerless grinding, 11-26 (Table 11-7)
centerless, thread, 12-122
cutoff, abrasive, 11-122 (Table 11-23)
cylindrical grinding, 11-28 (Table 11-8)
dressing
3-9)
form grinding, 11-32
jig grinding, 11-98
methods, 11-32 (Fig. 11-14), 11-69
types, 11-27
drill sharpening, 9-99
electrical discharge grinding, 14-62
electrochemical discharge grinding, 14-16
electrochemical grinding, 14-18
faces, standard, 11-18, 11-23(Fig. I1-12)
grade, 11-16, 11-69
grain size, 11-16
guarding, 11-33
hard-acting, characteristics, I 1-17 (Table
hob sharpening, 13-62
infeed or downfeed, 11-24
inspection, 11-18
internal grinding, 11-29 (Table 11-9)
jig grinding, 11-98
marking systems, 11-18, 11-19 (Fig. 11-81,
mounting, 11-18
for polycrystalline diamond, 3-45
safety, 11-33
shapes, standard, 11-18,11-21 (Fig. 11-10),
sharpening milling cutters, 10-67
soft-acting, characteristics, 11-17 (Table
11-4)
11-20 (Fig. 11-9) 11-22 (Table 11-5)
11-22 (Fig. 11-11)
11-3)
Wheels, grinding (cont.)
speed, maximum, 11-34, 11-36 (Table
speed, operating, 11-23
storage, 11-33
structure, 11-18
surface grinding, 11-25 (Table 11-6)
thread grinding, 12-118
toolroom grinding, 9-99, 11-30 (Table 11-
wheel-fluid interaction, 11-46
work speed, 11-24, 11-69
11-13)
lo), 11-92
Wick oiler, 4-50 (Fig. 4-22 and Fig. 4-23)
Wire cutting, electrochemical, 14-29 (Fig.
Wobble broach, manufacturing of, 14-60
Wood, compressed
14-3I)
carbide cutting tools, classifications, 3-22
hydrodynamic machining, 14-9 (Table
carbide cutting tools, classifications, 3-22
end milling, 10-56(Table 10-8)
hydrodynamic machining, 14-9 (Table 14-
carbide cutting tools, classifications, 3-22
end milling, 10-56 (Table 10-8)
hydrodynamic machining, 14-9 (Table 14-
(Table 3-11)
14-4)
Wood, hard
(Table 3-11)
4 and Fig. 14-8)
(Table 3-11)
Wood, soft
4 and Fig. 14-8)
Word-address format, 5-43
Work cells, robotic, 16-16, 16-17 (Fig. 16-16)
Work cutting stiffness, 11-14
Work, metalcutting
equations, 1-11 (Table 1-1)
work done vs. feed rate, 1-12 (Fig. 1-25)
work done in overcoming friction vs. feed
rate, orthogonal cutting, 1-12(Fig. 1-24),
work done in shearing vs. feed rate, orthogonal cutting, 1-12 (Fig. 1-23), 1-13
1-14
Work removal parameter, 11-13 (Fig. 11-6)
Work speed, grinding, 11-69
Workholding
bandsawing, 6-23, 6-24 (Fig. 6-22)
bevel gear cutting, 13-85
boring, 8-95
broaching, 7-32
circular sawing, 6-40, 6-41 (Fig. 6-31)
cylindrical grinding, 11-87
drilling, 9-69
electrochemical machining, 14-34
electron beam machining, 14-41
flexible manufacturing systems, 15-89(Fig.
gundrilling, 9-60 (Fig. 9-54)
hacksawing, 6-6, 6-7 (Fig. 6-6)
hobbing, 13-48
jig boring, 8-104
machining centers, 15-71 (Fig. 15-86 and
Fig. 15-87)
milling, 10-45
photochemical machining, 14-92
planing, 7-42
reaming, 9-125
safety, 18-11
shapers, gear, 13-65, 13-75
shaping and slotting, 7-52 (Fig. 7-65)
single-crystal diamond tools, 3-39
single-spindle automatic lathes, 15-5 (Fig.
single-spindle automatic screw machines,
15-22 (Fig. 15-13)
surface grinding, 11-60
tapping, 12-98
15-111)
15-5)
Workholding (cont.)
tool grinding, 11-92
turning, 8-47
vertical boring machines and turret lathes,
blank design, 13-29
machine tools, 13-30 (Fig. 13-26 and Fig.
principles, 13-29
rolling fluid, 13-30
15-60
Worm rolling
13-27)
x-Y-z
X-rays, 14-71
Young’s modulus, titanium carbide, 3-26
(Table 3-14)
Zero1 gears, 13-13, 13-77
Zinc and alloys
broaching constant, 7-22 (Table 7-5)
carbide-tipped boring tools, 8-86 (Table
drilling, spade, 9-94 (Table 9-23)
drilling, twist, 9-90 (Table 9-20), 9-103
face and back-off angles, HSS broaches,
machinability ratings, 1-49 (Table 1-10)
milling, 10-35 (Table 10-2)
photolsilk screen resist etchants, 14-84
polycrystalline diamond tools, 3-43
reaming, carbide-tipped, 9-114(Table9-39)
reaming, HSS reamers, 9-128 (Table 9-44)
tapping, 12-90,12-91 (Table 12-45), 12-102
thread chasing, I2-58,12-59 (Table 12-28),
unit power, single-point turning, 8-65
8-22)
7-18 (Table 7-4)
(Table 14-28)
(Table 12-51)
12-63, 12-64(Table 12-31)
(Table 8-17)
Zirconium and alloys
abrasive cutoff wheels, 11-122(Table11-23)
drilling, small-hole, 9-89
grinding wheels, centerless, 11-26 (Table
milling, 10-35 (Table 10-2)
additive in ceramic inserts, 3-32
coated abrasives, 11-41
I I-7)
Zirconium oxide
Zirconium oxide/aluminum oxide cofusion
abrasive

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