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 Fundamentals of
Machining Processes
Fundamentals of Machining
Processes
Conventional and Nonconventional
Processes

Third Edition

Hassan El-Hofy
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742

© 2019 by Taylor & Francis Group, LLC

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 Library of Congress Cataloging-in-Publication Data
Names: El-Hofy, Hassan, author.
Title: Fundamentals of machining processes: conventional and
nonconventional
processes/by Hassan El-Hofy.
Description: Third edition. | Boca Raton, FL: CRC Press/Taylor & Francis
Group,
[2019] | Includes bibliographical references and index.
Identifiers: LCCN 2018028484| ISBN 9781138334908 (hardback: acid-free
paper) |
ISBN 9780429443329 (ebook)
Subjects: LCSH: Machining.
Classification: LCC TJ1185 .E448 2019 | DDC 671.3/5—dc23
LC record available at https://lccn.loc.gov/2018028484

Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com

and the CRC Press Web site at http://www.crcpress.com

 I dedicate this edition of the book
to
The Soul of my late wife Soaad El-Hofy
and
My grandchildren
Omer, Youssef, Zaina, Hassan, Hana, and Ali
Contents
Preface
Foreword
Acknowledgments
Abbreviations
List of Symbols
Greek Symbols
Author

Chapter 1 Machining Processes

1.1 Introduction
1.2 Historical Background
1.3 Classification of Machining Processes
1.3.1 Machining by Cutting
1.3.1.1 Form Cutting
1.3.1.2 Generation Cutting
1.3.1.3 Form and Generation Cutting
1.3.2 Machining by Abrasion
1.3.3 Machining by Erosion
1.3.3.1 Chemical and Electrochemical
Erosion
1.3.3.2 Thermal Erosion
1.3.4 Hybrid Machining
1.3.5 Micromachining
1.3.6 Assisted Machining Processes
1.4 Machining Hard-to-Cut Materials
1.5 Variables of Machining Processes
1.6 Machining Process Selection
 1.7 Review Questions

Chapter 2 Cutting Tools

2.1 Introduction
2.2 Geometry of Single-Point Tools
2.2.1 American Standard Association (Tool-in-
Hand) (Coordinate) System
2.2.2 Tool Angles in Orthogonal System of Planes
2.2.3 Relationship between the ASA and
Orthogonal Systems
2.2.4 Effect of Tool Setting
2.2.5 Effect of Tool Feed Motion
2.2.6 Solved Example
2.3 Geometry of Multipoint Cutting Tools
2.3.1 Twist Drills
2.3.2 Reamers
2.3.3 BroachTools
2.3.4 End Mills
2.3.5 Plain Milling Cutters
2.4 Tool Materials
2.4.1 Requirements of Tool Materials
2.4.2 Classification of Tool Materials
2.4.2.1 Ferrous Tool Materials
2.4.2.2 Nonferrous Tool Materials
2.4.2.3 Nanocoated Tools
2.5 Problems
2.6 Review Questions

Chapter 3 Mechanics of Orthogonal Cutting

3.1 Introduction
3.2 Chip Formation
3.2.1 Discontinuous Chip
 3.2.2 Continuous Chip
3.2.3 Continuous Chip with a Built-up Edge
3.3 Orthogonal Cutting
3.3.1 Force Diagram
3.3.2 Shear Angle
3.3.3 Shear Stress
3.3.4 Velocity Relations
3.3.5 Shear Strain
3.3.6 Rate of Strain
3.3.7 Theory of Ernst and Merchant
3.3.8 Theory of Lee and Shaffer
3.3.9 Experimental Verification
3.3.10 Energy Consideration
3.3.11 SolvedExample
3.4 Heat Generation in Metal Cutting
3.4.1 Cutting Tool Temperature
3.4.2 Temperature at Shear Plane
3.4.3 Factors Affecting the Tool Temperature
3.4.3.1 Machining Conditions
3.4.3.2 Cutting Tool
3.4.3.3 Cutting Fluids
3.4.3.4 Minimum Quantity Lubrication
3.4.4 SolvedExample
3.5 Problems
3.6 Review Questions

Chapter 4 Tool Wear, Tool Life, and Economics of Metal Cutting

4.1 Tool Wear
4.1.1 Introduction
4.1.2 Forms of Tool Wear
4.1.2.1 Crater Wear
4.1.2.2 Flank Wear
 4.1.3 Impact of Tool Wear
4.2 ToolLife
4.2.1 Formulation of Tool-life Equation
4.2.2 Criteria for Judging the End of Tool Life
4.2.3 Factors Affecting Tool Life
4.2.3.1 Cutting Conditions
4.2.3.2 Tool Geometry
4.2.3.3 Built-Up Edge Formation
4.2.3.4 Tool Material
4.2.3.5 Workpiece Material
4.2.3.6 Rigidity of the Machine Tool
4.2.3.7 Coolant
4.2.4 Solved Example
4.3 Economics of Metal Cutting
4.3.1 Cutting Speed for Minimum Cost
4.3.2 Cutting Speed for Minimum Time
4.3.3 Cutting Speed for Maximum Profit Rate
4.3.4 Solved Example
4.4 Problems
4.5 Review Questions

Chapter 5 Cutting Cylindrical Surfaces

5.1 Introduction
5.2 Turning
5.2.1 Cutting Tools
5.2.2 Cutting Speed, Feed, and Machining Time
5.2.3 Elements of Undeformed Chip
5.2.4 Cutting Forces, Power, and Removal Rate
5.2.5 Factors Affecting the Turning Forces
5.2.5.1 Factors Related to Tool
5.2.5.2 Factors Related to Workpiece
 5.2.5.3 Factors Related to Cutting
Conditions
5.2.6 Surface Finish
5.2.7 Assigning the Cutting Variables
5.2.8 Solved Example
5.3 Drilling
5.3.1 Drill Tool
5.3.2 Elements of Undeformed Chip
5.3.3 Cutting Forces, Torque, and Power
5.3.4 Factors Affecting the Drilling Forces
5.3.4.1 Factors Related to the Workpiece
5.3.4.2 Factors Related to the Drill
Geometry
5.3.4.3 Factors Related to Drilling
Conditions
5.3.5 Drilling Time
5.3.6 Dimensional Accuracy
5.3.7 Surface Quality
5.3.8 Selection of Drilling Conditions
5.3.9 Solved Example
5.4 Reaming
5.4.1 Finish Reamers
5.4.2 Elements of Undeformed Chip
5.4.3 Forces, Torque, and Power in Reaming
5.4.4 Reaming Time
5.4.5 Selection of the Reamer Diameter
5.4.6 Selection of Reaming Conditions
5.4.7 Solved Example
5.5 Problems
5.5.1 Turning
5.5.2 Drilling
5.6 Review Questions
Chapter 6 Cutting Flat Surfaces
6.1 Introduction
6.2 Shaping and Planing
6.2.1 Shaper and Planer Tools
6.2.2 Elements of Undeformed Chip
6.2.3 Cutting Forces, Power, and Removal Rate
6.2.4 Shaping Time
6.2.5 Selection of Cutting Variables
6.2.6 Solved Example
6.3 Milling
6.3.1 Horizontal (Plain) Milling
6.3.1.1 Plain-Milling Cutters
6.3.1.2 Cutting Speed of Tool and
Workpiece Feed
6.3.1.3 Elements of Undeformed Chip
6.3.1.4 Forces and Power in Milling
6.3.1.5 Surface Roughness in Plain Milling
6.3.1.6 Milling Time
6.3.1.7 Factors Affecting the Cutting Forces
6.3.1.8 Solved Example
6.3.2 Face Milling
6.3.2.1 Face-Milling Cutters
6.3.2.2 Elements of Undeformed Chip
6.3.2.3 Surface Roughness
6.3.2.4 Machining Time
6.3.2.5 Solved Example
6.3.3 Selection of Milling Conditions
6.4 Broaching
6.4.1 Broach Tool
6.4.2 Chip Formation in Broaching
6.4.3 Broaching Force and Power
6.4.4 Broaching Time
6.4.5 Accuracy and Surface Finish
 6.4.6 Broach Devsign
6.4.7 Solved Example
6.5 Problems
6.5.1 Shaping
6.5.2 Horizontal Milling
6.5.3 Vertical Milling
6.5.4 Broaching
6.6 Review Questions

Chapter 7 High-Speed Machining

7.1 Introduction
7.2 History of HSM
7.3 Chip Formation in HSM
7.4 Characteristics of HSM
7.5 Machining-Related Measurements
7.5.1 Force Measurement
7.5.1.1 Dynamometers Based on
Displacement Measurement
7.5.1.2 Dynamometers Based on Strain
Measurement
7.5.1.3 Piezoelectric (Quartz)
Dynamometers
7.5.2 Vibration Measurements
7.5.3 Temperature Measurements
7.5.3.1 Thermocouple Techniques
7.5.3.2 Infrared Techniques
7.5.4 Tool Wear Measurements
7.6 Applications of HSM
7.7 Advantages of HSM
7.8 Limitations of HSM
7.9 Review Questions

Chapter 8 Machining by Abrasion

8.1 Introduction
8.2 Grinding
8.2.1 Grinding Wheels
8.2.1.1 Abrasive Materials
8.2.1.2 Grain Size
8.2.1.3 Wheel Bond
8.2.1.4 Wheel Grade
8.2.1.5 Wheel Structure
8.2.1.6 Grinding-Wheel Designation
8.2.1.7 Wheel Shapes
8.2.1.8 Selection of Grinding Wheels
8.2.1.9 Wheel Balancing
8.2.1.10 Truing and Dressing
8.2.1.11 Temperature in Grinding
8.2.2 Wheel Wear
8.2.3 Economics of Grinding
8.2.4 Surface Roughness
8.3 Surface Grinding
8.3.1 Elements of Undeformed Chip
8.3.2 Grinding Forces, Power, and Removal Rate
8.3.3 Factors Affecting the Grinding Forces
8.3.4 Grinding Time
8.3.5 Solved Example
8.3.6 Surface Grinding Operations
8.3.6.1 Plain (Periphery) and Face Grinding
with Reciprocating Feed
8.3.6.2 Surface Grinding with a Rotating
Table
8.3.6.3 Creep-Feed Grinding
8.4 CylindricalGrinding
8.4.1 Elements of Undeformed Chip
8.4.2 Forces, Power, and Removal Rate
8.4.3 Factors Affecting the Grinding Forces
 8.4.4 Factors Affecting Surface Roughness
8.4.5 Solved Example
8.4.6 Cylindrical Grinding Operations
8.4.6.1 External Cylindrical Grinding
8.4.6.2 External Centerless Grinding
8.4.6.3 Internal Cylindrical Grinding
8.4.6.4 Internal Centerless Grinding
8.5 Wheel Speed and Workpiece Feed
8.6 Problems
8.7 Review Questions

Chapter 9 Abrasive Finishing Processes

9.1 Introduction
9.2 Honing
9.2.1 Honing Kinematics
9.2.2 Process Components
9.2.3 Process Description
9.2.4 Process Characteristics
9.3 Lapping
9.3.1 Process Components
9.3.2 Mechanics of Lapping
9.3.3 Process Characteristics
9.3.4 Lapping Operations
9.4 Superfinishing
9.4.1 Kinematics of Superfinishing
9.4.2 Process Characteristics
9.5 Polishing
9.6 Buffing
9.7 Review Questions

Chapter 10 Modern Abrasive Processes

10.1 Ultrasonic Machining
 10.1.1 Mechanism of Material Removal
10.1.2 Solved Example
10.1.3 Factors Affecting Material Removal Rate
10.1.4 Dimensional Accuracy
10.1.5 Surface Quality
10.1.6 Applications
10.2 Abrasive Jet Machining
10.2.1 Material Removal Rate
10.2.2 Applications
10.3 Abrasive Water Jet Machining
10.3.1 Process Characteristics
10.4 Abrasive Flow Machining
10.5 Problems
10.6 Review Questions

Chapter 11 Magnetic Field-Assisted Finishing Processes

11.1 Introduction
11.2 Magnetic Abrasive Finishing
11.2.1 Process Description
11.2.2 Process Characteristics
11.2.2.1 Material Removal Rate and Surface
Finish
11.2.2.2 Applications
11.3 Magnetic Float Polishing
11.4 Magnetorheological Finishing
11.5 Magnetorheological Abrasive Flow Finishing
11.6 Review Questions

Chapter 12 Mass Finishing Operations

12.1 Introduction
12.2 Process Components
12.2.1 Media
 12.2.2 Compounds
12.3 Mechanical Mass Finishing
12.3.1 Barrel Finishing
12.3.2 Vibratory Finishing
12.3.3 Centrifugal Barrel Finishing
12.3.4 Centrifugal Disc Finishing
12.3.5 Spindle Finishing
12.4 Electrochemical Mass Finishing
12.4.1 Machining Principles
12.4.2 Factors Affecting Material Removal
12.4.3 Applications
12.5 Electropolishing
12.6 Review Questions

Chapter 13 Machining by Electrochemical Erosion

13.1 Introduction
13.2 Principles of ECM
13.3 Advantages and Disadvantages of ECM
13.3.1 Advantages
13.3.2 Disadvantages
13.4 Material Removal Rate by ECM
13.5 Solved Example
13.6 ECM Equipment
13.7 Process Characteristics
13.8 Economics of ECM
13.9 ECM Applications
13.10 Chemical Machining
13.11 SolvedExample
13.12 Problems
13.13 Review Questions

Chapter 14 Machining by Thermal Erosion

 14.1 Introduction
14.2 Electrodischarge Machining
14.2.1 Mechanism of Material Removal
14.2.2 EDM Machine
14.2.3 Material Removal Rates
14.2.4 Surface Integrity
14.2.5 Heat-Affected Zone
14.2.6 Applications
14.3 Laser Beam Machining
14.3.1 Material Removal Mechanism
14.3.2 Solved Example
14.3.3 Applications
14.4 Electron Beam Machining
14.4.1 Material Removal Process
14.4.2 Solved Example
14.4.3 Applications
14.5 Ion Beam Machining
14.6 Plasma Beam Machining
14.6.1 Material Removal Rate
14.6.2 Applications
14.7 Problems
14.8 Review Questions

Chapter 15 Hybrid Machining Processes

15.1 Introduction
15.2 Hybrid Electrochemical Processes
15.2.1 Electrochemical Grinding
15.2.2 Electrochemical Honing
15.2.3 Electrochemical Superfinishing
15.2.4 Electrochemical Buffing
15.2.5 Ultrasonic-Assisted Electrochemical
Machining
 15.3 Hybrid Thermal Proces ses
15.3.1 Electroerosion Dissolution Machining
15.3.2 Abrasive Electrodischarge Grinding
15.3.3 Abrasive Electrodischarge Machining
15.3.4 EDM with Ultrasonic Assistance
15.3.5 Electrochemical Discharge Grinding
15.3.6 Brush Erosion Dissolution Mechanical
Machining
15.4 Problems
15.5 Review Questions

Chapter 16 Micromachining
16.1 Introduction
16.2 Conventional Micromachining
16.2.1 Diamond Microturning
16.2.2 Microdrilling
16.3 Abrasive Micromachining
16.3.1 Microgrinding
16.3.2 Magnetic Abrasive Microfinishing
16.3.3 Microsuperfinishing
16.3.4 Microlapping
16.3.5 Micro-Ultrasonic Machining
16.4 Nonconventional Micromachining
16.4.1 Micromachining by Thermal Erosion
16.4.1.1 Micro-EDM
16.4.1.2 Laser Micromachining
16.4.2 Micromachining by Electrochemical Erosion
16.4.3 Hybrid Micromachining Processes
16.4.3.1 Chemical-Assisted Mechanical
Polishing
16.4.3.2 Mechanochemical Polishing
16.4.3.3 Electrolytic In-process Dressing of
Grinding Wheels
 16.5 Review Questions

Chapter 17 Machining Composite Materials

17.1 Introduction
17.2 Reinforcing Materials
17.3 Matrix
17.4 Machining of Composites
17.5 Chip Formation
17.5.1 Cutting Particulate-Reinforced Composites
17.5.2 Cutting Unidirectional Composites
17.5.2.1 Sharp-Edged Tools
17.5.2.2 Nose Radiused Tools
17.5.3 Cutting Multidirectional Composites
17.6 Traditional Machining Operations
17.6.1 Turning
17.6.2 Drilling
17.6.3 Milling and Trimming
17.6.4 Grinding
17.7 Nontraditional Machining
17.7.1 Abrasive Water Jet Machining
17.7.2 Laser Beam Machining
17.7.3 Electrodischarge Machining
17.8 Machining Defects
17.9 Problems
17.10 Review Questions

Chapter 18 Vibration-Assisted Machining

18.1 Introduction
18.2 Kinematics of VAM
18.2.1 1-DVAM
18.2.2 2-D VAM
18.3 Advantages of VAM
 18.4 Vibration-Assisted Conventional Machining
18.4.1 Turning
18.4.2 Drilling
18.4.3 Milling
18.4.4 Grinding
18.5 Nonconventional Vibration-Assisted Machining
18.5.1 Electrodischarge Machining
18.5.2 Electrochemical Machining
18.5.3 Abrasive Waterjet Machining
18.6 Review Questions

Chapter 19 Machinability
19.1 Introduction
19.2 Conventional Machining
19.2.1 Judging Machinability
19.2.2 Relative Machinability
19.2.3 Factors Affecting Machinability
19.2.3.1 Condition of Work Material
19.2.3.2 Physical Properties of Work
Materials
19.2.3.3 Machining Parameters
19.2.4 Machinability of Engineering Materials
19.2.4.1 Machinability of Steels and Alloy
Steels
19.2.4.2 Machinability of Cast Irons
19.2.4.3 Machinability of Nonferrous Metals
and Alloys
19.2.4.4 Machinability of Nonmetallic
Materials
19.3 Nonconventional Machining
19.4 Review Questions

Chapter 20 Machining Process Selection

 20.1 Introduction
20.2 Factors Affecting Process Selection
20.2.1 Part Features
20.2.2 Part Material
20.2.3 Dimensional and Geometric Features
20.2.4 Surface Texture
20.2.5 Surface Integrity
20.2.6 Production Quantity
20.2.7 Production Cost
20.2.8 Environmental Impacts
20.2.9 Process and Machine Capability
20.3 Review Questions
References
Index
Preface

Machining processes produce finished parts, ready for use or

assembly, at a high degree of accuracy and surface quality by
removing a certain machining allowance from the workpiece
material. The removal of material can be achieved by cutting
abrasion and erosion. Nonconventional machining by erosion of the
workpiece material regardless of their mechanical properties has
emerged to overcome the drawbacks of conventional machining
processes. Hybrid machining processes combine more than one
process together to achieve higher machining rates, greater product
accuracy, and the best possible surface characteristics. New hard-to-
cut materials made it essential to adopt new machining methods
such as vibration-assisted machining. The fundamentals of
machining composite materials with high strength-to-weight ratio
have to be addressed. Techniques of mass finishing operations need
to be covered.
Many aspects of the machining subject have been covered in
detail and in a scattered way through various
machining/manufacturing books, and the author believes that this
new edition covers a complete set of machining topics at this level in
a single book.
I am glad to present this new revised edition as an outcome to
various suggestions and comments received from readers,
researches, and professors of various universities. This new edition
covers the fundamentals of machining by cutting, abrasion, erosion,
and combined processes; high-speed machining, micromachining,
machinability concepts; and machining process selection guidelines.
Four extra chapters have been added dealing with magnetic-assisted
finishing, mass finishing, machining of composites, and vibration-
assisted machining.
This new edition is a fundamental textbook for undergraduate
students enrolled in production, materials, industrial, mechatronics,
marine, and mechanical engineering programs. Additionally, students
from other disciplines may find this book helpful with courses in the
area of manufacturing engineering. It is also useful for students
enrolled in graduate programs related to higher level machining
topics. Professional engineers and technicians working in the field of
machining technology will find it of value as well. The treatment of
the different subjects has been developed from basic principles and
does not require knowledge of advanced mathematics as a
prerequisite. Along with fundamental theoretical analysis, this book
contains machining data, solved examples, and review questions
which are useful for students and manufacturing engineers. A
solutions manual and power-point presentations are supplied with
the book to help those adopting it.
The book is divided into 20 chapters as listed below. A brief
description of each follows the list.

Chapter 1 Machining Processes

Chapter 2 Cutting Tools
Chapter 3 Mechanics of Orthogonal Cutting
Chapter 4 Tool Wear, Tool Life, and Economics of Metal Cutting
Chapter 5 Cutting Cylindrical Surfaces
Chapter 6 Cutting Flat Surfaces
Chapter 7 High-Speed Machining
Chapter 8 Machining by Abrasion
Chapter 9 Abrasive Finishing Processes
Chapter 10 Modern Abrasive Processes
Chapter 11 Magnetic Field–Assisted Finishing Processes
Chapter 12 Mass Finishing Processes
Chapter 13 Machining by Electrochemical Erosion
 Chapter 14 Machining by Thermal Erosion
Chapter 15 Hybrid Machining Processes
Chapter 16 Micromachining
Chapter 17 Machining Composite Materials
Chapter 18 Vibration-Assisted Machining
Chapter 19 Machinability
Chapter 20 Machining Process Selection

Chapter 1 introduces the history and progress of machining. The

importance of machining in manufacturing technology and variables
of machining processes are presented. The basics of machining by
cutting, abrasion, and erosion are explained and examples are given.
Chapter 2 describes the geometry of single-point and multipoint
cutting tools, tool materials, properties, selection, and machining
conditions.
Chapter 3 covers the mechanics of orthogonal cutting including
chip formation and the different theories describing the cutting
forces, stresses, and material removal process. It discusses heat
generation in metal cutting, cutting tool temperature, and cutting
fluids.
Chapter 5 describes the mechanics of the machining processes
used for cutting cylindrical surfaces including turning, drilling, and
reaming. For each process, the cutting force, power consumption,
machining time, volumetric removal rate, and surface roughness are
evaluated.
Chapter 4 discusses tool wear, tool life, and the economics of
machining processes. The specific cutting speed for minimum cost,
maximum production rate/minimum time, and maximum profit rate
are quantitatively determined.
Chapter 6 covers processes used to cut flat surfaces, such as
shaping, milling, and broaching where cutting forces, power
consumption, cutting time, surface roughness, and material removal
rates are calculated.
Chapter 7 presents a concise introduction to high-speed
machining (HSM) where chip formation and process characteristics
are explained. Methods of force, vibrations, temperature, and tool
wear measurements are presented. Industrial applications,
advantages, and limitations of HSM are also discussed.
Chapter 8 presents the principles of machining by abrasion. It
includes the theoretical basis of the grinding process including
grinding wheel description, selection, balancing, wear, dressing, and
truing, in addition to the economics of grinding. Elements of the
undeformed chip, grinding forces, power, time, and removal rate are
analyzed for both surface and cylindrical grinding applications.
Chapter 9 presents the abrasive finishing processes that are used
for superfinishing parts produced by reaming or grinding. The
kinematics, characteristics, and applications of honing, lapping,
super finishing, polishing, and buffing are described.
Chapter 10 introduces modern abrasive processes including
ultrasonic machining, abrasive jet machining, abrasive water jet
machining (AWJM), and abrasive flow machining.
Chapter 11 covers the magnetic field–assisted finishing processes
including magnetic abrasive finishing, magnetic float polishing,
magnetorhelogical finishing, and magnetorhelogical abrasive flow
finishing. For each process, its description, characteristics, material
removal, accuracy, and surface quality are discussed.
Chapter 12 covers mass finishing processes including vibratory
finishing, barrel finishing, centrifugal barrel finishing, centrifugal disc
finishing, spindle finishing, electrochemical mass finishing, and
electro polishing.
Chapter 13 explores machining by chemical and electrochemical
erosion. The principles of chemical machining and electrochemical
machining (ECM) are described. Machining systems, process
characteristics, and industrial applications are also covered.
Chapter 14 covers the machining processes that utilize a thermal
effect for melting and evaporation of the workpiece material. In this
regard, material removal mechanisms, accuracy, surface
characteristics, and applications for electrodischarge machining
(EDM), laser beam machining (LBM), electron beam machining
(EBM), ion beam machining (IBM), and plasma jet machining are
explained.
Chapter 15 covers the hybrid machining processes that combine
more than one machining effect; these processes are based on
either electrochemical or thermal erosion that are mostly assisted by
mechanical abrasion action. Electrochemical grinding, honing,
superfinishing, ultrasonic, and buffing are typical examples of hybrid
electrochemical processes. Hybrid thermal processes include
electrochemical discharge grinding, abrasive electrodischarge
grinding, ultrasonic-assisted electrodischarge machining, and
mechanical brush erosion dissolution machining.
Chapter 16 covers micromachining by cutting processes that
include diamond microturning and microdrilling. Abrasive
micromachining processes, such as microgrinding, magnetic abrasive
micromachining and finishing, microsuperfinishing, microlapping, and
microultrasonic machining are presented. Nonconventional
micromachining by thermal erosion (micro-EDM and laser
micromachining), micromachining by electrochemical erosion, and
hybrid micromachining processes are also covered.
Chapter 17 introduces machining composite materials, machining
defects, chip formation, cutting particulate reinforced composites,
cutting unidirectional composites, cutting multidirectional
composites, turning, drilling, milling, grinding, and trimming of
composites, nontraditional machining by AWJ machining, laser
machining, EDM, and vibration-assisted nonconventional machining
by EDM and ECM
Chapter 18 presents the kinematics of vibration-assisted
machining (VAM), advantages of VAM, and vibration-assisted
conventional machining in turning, milling, drilling, and grinding.
Vibration-assisted nonconventional machining by EDM, ECM, and
AWJM are presented.
Chapter 19 explains the definition of the relative machinability
index and how the machinability is judged. It illustrates the
important factors affecting the machinability ratings. It also presents
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