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Specialized Books on Machining

Cutting Data for Turning of Steel

Cutting Data for Turning of Steel
Edmund Isakov
250 pages, Illustrated
Published: October, 2008

Machining is one of the most important manufacturing processes, which remove unwanted material in the form of chips from a workpiece. Material removal operations are among the most expensive; in the U.S. alone, more than $100 billion were spent on machining in 1999. These high costs put tremendous economic pressures on production managers and engineers as they struggle to find ways to increase productivity.

Machining recommendations provided in this book cover turning since it allows removing more material per unit of time and consuming more power at the roughing operations than end milling, boring or drilling. Machining recommendations relate to cutting speeds, feed rates, and depth of cuts. Such recommendations depend on the workpiece material properties and the cutting tool material. Workpiece materials described in this book are the most commonly used grades of carbon, alloy, stainless, tool, and maraging steels. Cutting tool materials are cemented carbides, cermets, and ceramics.

* Describes hardness, tensile strength, and machinability of steels-the major mechanical properties. These properties are taken into consideration when selecting machining parameters.
* Features machining recommendations for turning that provide the cutting speed values based on Brinell hardness numbers, the depth of cut, and feed rate in relationships with the type of steel.
* Summarizes numerous calculations in five appendices.

Table of Contents:

Mechanical Properties of Steel
* Hardness
* Carbon Steels
* Alloy Steels
* Stainless Steels
* Tool Steels

Cutting Tools Materials
* High Speed Steels
* Cemented Carbides
* Cermets
* Ceramics
* Polycrystalline Cubic Boron Nitride (PCBN)

Machining Recommendations
* Depth of Cut and Feed Rate
* Cutting Speeds for Carbon Steels
* Cutting Speeds for Alloy Steels
* Cutting Speeds for Stainless Steels
* Cutting Speeds for Tool Steels

Machining Power
* Metal Removal Rate
* Unit Power and Power Constant
* Calculating Required Machining Power

Appendix 1: Hardness Conversion

Appendix 2: Carbon Steels

Appendix 3: Alloy Steels

Appendix 4: Stainless Steels

Appendix 5: Tool Steels
Quantity Price Model Description

$49.40 BK-DATA
Cutting Data for Turning of Steel

Countersinking Handbook

Countersinking Handbook
LaRoux Gillespie
200 pages, Illustrated
Published: March, 2008

This unique handbook provides total coverage of issues related to countersinking and chamfering holes, including history of their use, design reasons, and basic cutter design. It features “how-to-use” details of the most used tools and techniques and complete information on the subject of countersinking holes of any size, including those over 10 inches in diameter. Its detailed approach to illustrating over 100 different tools designs is unparalleled in technical literature and is sure to be found useful by manufacturing engineers, shop foremen, and experienced users.

* Provides discussions of all cutter material variations and options, feeds, speeds and coolants, tool holders, and applications--including plastics, metals, wood, composites, ceramics, glass, and dental materials.
* Discusses side effects of countersinking, including stress risers.
* Includes optimum applications for specific tool use, gaging countersinks, economics, pressworking countersinks, non-traditional countersinking methods, and references to standards and other published works.
* Contains case histories, practical tips, and information to make process selection easier.

Table of Contents:

* History of Countersinking
* Design Reasons for Countersinking
* Cutter Designs
* Feeds, Speeds, Cutting Forces, and Tool Life, Driving and Holding the Tools
* Applications
* Product Material Issues
* Surface and Subsurface Effects of Countersinks
* Selecting the Best Tool Design
* Inspection of Countersink Features
* Economics
* Pressworking (Dimpling) Countersinking
* Other Means of Making Countersinks
* Appendix A: Patents for Countersink-Related Items
* Appendix B: Standards Related to Countersink
* Appendix C: Countersink Cutter Design
* Appendix D: Manufacturer Names and Contact Information
* Index
Quantity Price Model Description

$71.90 BK-CSINK
Countersinking Handbook

Secrets of 5-Axis Machining

Secrets of 5-Axis Machining
Karlo Apro
176 pages
Published: October, 2008

Up to now, the best way to get information on 5-axis machining has been by talking to experienced peers in the industry, in hopes that they will share what they learned. Visiting industrial tradeshows and talking to machine tool and Cad/Cam vendors is another option, only these people will all give you their point of view and will undoubtedly promote their machine or solution.

This unbiased, no-nonsense, to-the-point description of 5-axis machining presents information that was gathered during the author's 30 years of hands-on experience in the manufacturing industry, bridging countries and continents, multiple languages - both human and G-Code. As the only book of its kind, Secrets of 5-Axis Machining will demystify the subject and bring it within the reach of anyone who is interested in using this technology to its full potential, and is not specific to one particular CAD/CAM system. It is sure to empower readers to confidently enter this field, and by doing so, become better equipped to compete in the global market.

* Features full-color illustrations through that help to explain the theories and principals.
* Includes a CD containing avi files, high quality illustrations, and sample parts.

Table of Contents:

* Introduction
* Common Misconceptions
* Know Your Machine
* Cutting Strategies
* Indexing Work
* Simultaneous Work
* Machine Simulation
* Choosing a Machine for Your Application
* Choosing a CAD/CAM System for Your Application
* Machine and CAD/CAM System Configuration
Quantity Price Model Description

$54.95 BK-5AXIS
Secrets of 5-Axis Machining

Grinding Technology

Grinding Technology
Stephen Malkin/Changsheng Guo
375 pages, Illustrated
Published: May, 2008
Presenting a comprehensive and consistent treatment of grinding theory and its practical utilization, this new edition focuses on grinding as a machining process using bonded abrasive grinding wheels as the cutting medium. Logically organized, this self-contained resource starts with a description of abrasives and bonded abrasive cutting tools; then moves on to thermal analyses of the grinding process for conventional, creep feed, and superabrasive grinding; and ends with methods for enhancing and optimizing of grinding operations, simulation of grinding processes, and computer control of grinding machines. The perfect reference for practicing engineers involved in the grinding process, it will also be useful for researchers working in the field.

* Features a unified and self-contained presentation about what is known about grinding processes and how this information can be practically applied.
* Presents more detail on new grain materials, creep feed conventional abrasive wheels, superabrasive (diamond and CBN) materials and wheels, and metal bonded superabrasive electroplated wheels.
* Includes a more comprehensive treatment of thermal aspects of grinding; as well as a new chapter on dealing with fluid flow in grinding—including flow through the grinding zone, fluid burnout, and cooling effects.
* Contains an updated chapter relating to grinding machine control and optimization with a new example of model-based grinding optimization, and future prospects for integrating simulation into open architecture machine tools for optimal control.

Table of Contents:

* Preface
* Introduction
* Grinding Wheels: Composition and Properties
* Grinding Geometry and Kinematics
* Wheel, Truing, Dressing, and Topography
* Grinding Mechanisms
* Thermal Aspects: Conventional Grinding
* Thermal Aspects: Creep-Feed Grinding
* Thermal Aspects: Grinding with CBN Abrasives
* Fluid Flow in Grinding
* Surface Roughness
* Wheel Wear and Lubrication
* Grinding Deflections: Grinding Cycles, Inaccuracies, and Vibrations
* Simulation, Optimization, and Intelligent Control
Quantity Price Model Description

$71.90 BK-GT
Grinding Technology

Advanced Metalcutting Calculators

Advanced Metalcutting Calculators & Engineering Formulas for Metalcutting, CD and Book Combo
Edmund Isakov
212 pages, Illustrated, 5 x 7
Published: June, 2005

OVERVIEW
Advanced Metalcutting Calculators contains four calculators for major metalcutting operations: Milling, Turning, Boring,
Drilling; and a fifth for calculating exact Machining Time when facing, cutting off, and deep grooving. All calculators are
developed in Microsoft Excel and execute all parameters in both U.S. and metric units. These calculators provide
computations more accurate than any other calculators on the market and can be used by anyone involved in
manufacturing, including machinists, technicians, and engineers.
Advanced Computations:
Power requirements when milling, turning, boring, or drilling are calculated by tangential force and cutting speed, or by
torque and the number of revolutions per minute. These requirements are calculated when cutting inserts are sharp and prior
to indexing or changing them

CONTENTS
MILLING CALCULATOR
* Cutting force versus ultimate tensile strength of the work material and area of the chip.
* Torque at spindle versus cutting force and the cutter diameter.
* Adjustments to feed rate depending on the cutter geometry and width of cut

TURNING CALCULATOR
* Cutting force components tangential force versus depth of cut, feed rate, and the work materials power constant; feed
and radial forces versus tangential force and the coefficients of proportionality, depending on the group of work materials.
* Torque at spindle versus tangential force and the workpiece diameter

BORING CALCULATOR (in addition to the same two features immediately above)
* Deflection versus resulting cutting force, unsupported length of the boring bar, moment of inertia of the bar cross-
sectional area, and the modulus of elasticity of the bar material. Note: The method of determining feed and radial forces
when turning and boring, and the calculators that utilize this method are patented (US Patent # 6,836,697)

DRILLING CALCULATOR
* Tangential force versus drill diameter, feed rate, power constant of the work material, and the drill wear factor.
* Thrust (axial force) versus tangential force and the coefficient of proportionality establishing thrust-to-tangential force
ratio.
* Torque at the drill versus tangential force and the drill diameter.

MACHINING TIME:
* Radius of the workpiece when the machine tool spindle runs at the maximum rpm.
* Machining time (in minutes) when facing or cutting off to the center of the workpiece; or when deep grooving, facing,
or cutting off to a shoulder of the workpiece.
Quantity Price Model Description

$75.95 BK-AMCCD
Advanced Metalcutting Calculators CD

Cam Design and Manufacturing Handbook

By Robert L. Norton, P.E.
2001, 7 3/8 X 9 1/4 illustrated hardcover
640 pages
Includes CD-ROM with 90-day trial demonstration copies of Dynacam, Fourbar, Sixbar, and Slider (cam and cam-follower linkage design programs)
OVERVIEW
Beginning at an introductory level and progressing to more advanced topics, this comprehensive handbook provides all the information needed to properly design, model, analyze, specify, and manufacture cam-follower systems. The reader will find complete coverage of:
Proper Cam Design Techniques
Single and Multi-Dwell Cams
Polynomial Cams
Spline Functions for Cams
Pressure Angle and Radius of Curvature
Radial and Barrel Cams
Translating and Oscillating Followers
Roller and Flat-Faced Followers
Forward and Inverse Dynamic Analyses
Residual Vibrations
Polydyne and Splinedyne Cams
Cam Profile Definition
Cutter Compensation
Conjugate Cams
Cam Materials and Manufacturing Techniques
Stress Analysis of the Cam Follower Joint
Lubrication of the Cam Follower Joint
Measurement of the Cam Follower Dynamics
Extensive Bibliography of the Cam Literature
Case Studies of Cam Designs
Quantity Price Model Description

$89.90 BK-CDMH
Cam Design and Manufacturing Handbook

Guide to Hard Milling and High Speed Machining

Guide to Hard Milling and High Speed Machining
Dale Mickelson
300 pages, Illustrated, 7 x 10
Published: October 2006

OVERVIEW
This volume is a continuation of Hard Milling & High Speed Machining: Tools of Change. It features different cutters developed for hard milling and high speed machining. In this current guide, you will find yet more variables associated with this process. Six machine manufacturers are covered in the first six chapters: Mikron, Okuma, Yasda, Roku Roku, Johnford and Moore. They explain the different approaches to building machines for this process. Also covered are two holder manufacturers Heartech Precision and Big Kaiser, one probe and laser manufacturer Blum. Furthermore the author includes some of his most recent development work done on hard-to-machine materials and new cutters on the market today.

CONTENTS
* Mikron
* Okuma America Corporation
* Yasda
* Roku-Roku
* Johnford Machines
* Moore Precision Tools
* Heartech Precision Inc., Advanced Tooling Systems
* BIG Kaiser: Dual Contact Spindle System Enhances Rigidity and Repeartability
* Blum Probes and Lasers
* Case Studies for Hard Milling and High Speed Machining
* Index
Quantity Price Model Description

$53.90 BK-HM
Guide to Hard Milling

The Metal Stamping Process

By Jim Szumera
2003, 6 X 9 illustrated hardcover
224 pages
Includes ProQuote cost-estimation program on floppy disk
OVERVIEW
This book is an invaluable resource for anyone involved in or preparing for a career in the metal forming industry. It was written by an expert with over 30 years of practical experience, and it has been used for years as the core reference for what is widely regarded as the premier training program in this industry. With this book you will have immediate access to metal working formulas, design standards, set up techniques, guidelines for designing and tolerancing parts, material choices, EDM, coatings, lubricants, problems and root causes, tooling tips, machine maintenance and mil standards. Also included is ProQuote, a complete and simple-to-use Excel program for cost estimating tools and parts. It will help ensure that your calculations are correct and save you time besides.
CONTENTS
The Distinct Groups of Metal Stamping
Part Design
Estimating and Quoting
Tool Design
Raw Material
Designing for Part Features
Forming and Bending Applications
Draw Forming
Designing for Performance
Tooling Enhancements for Performance
Pressroom Utilization
Troubleshooting
Die Electronics
Reference
Quantity Price Model Description

$62.90 BK-MESTPR
The Metal Stamping Process

Handbook of Manufacturing Processes

Handbook of Manufacturing Processes: How Products, Components, and Materials are Made
James G. Bralla
864 pages, Illustrated, 7 x 10
Published: January 2007

OVERVIEW
Far more ambitious than any similar reference, the Handbook of Manufacturing Processes is an in-depth compilation of the workings of more than 1500 manufacturing processes in the metalworking, chemicals, textiles, plastics, ceramics, electronics, wood, and food industries; as well as a wide-ranging presentation of how more than 600 important products, components, and materials are made. Logically organized in two sections—a process section and a products section—it describes clearly and succinctly the operations performed in the world’s factories. Heavily illustrated, it is an extraordinarily comprehensive source of technical manufacturing information. Manufacturing and process engineers, factory managers and supervisors, and anyone who has an interest in or needs to know about manufacturing operations and how products are made – including those not technically trained – will find in this book a treasure trove of useful information.

FEATURES
* Practical, understandable explanations, even for complex processes.
* Clear, jargon-free descriptions of how each of 1500 current and recently developed manufacturing processes work, what they do to the material or workpiece that is worked on, what the results are, and where these processes are used and why.
* Precise explanations of how 600 products, components, and materials are made
* Text entries that are coded as in an outline, with these alpha/numerical designations carried over to the related illustrations for easy cross-referencing.
* Related processes that are grouped together; and sequential operations that are covered in order.
* Contributions from an Editorial Board of 24 experts.
* More than 600 line drawings and photographs.
* A detailed table of contents and extensive index.

CONTENTS
Section I: Manufacturing Processes
* Casting Processes
* Metal Forming Processes
* Machining Processes
* Processes for Plastics
* Glass and Ceramic Processes
* Woodworking Processes
* Assembly and Fusion (or Joining) Processes
* Finishing Processes (including Heat Treating)
* Paper, Fiber, and Printing Processes
* Textile Processes
* Chemical Processes
* Food Processes
* Processes for Electronic Products
* Advanced Manufacturing Methods

Section II: How Products, Components and Materials Are Made
This section identifies the materials used, and describes the operation sequence and manufacturing methods for many important products, components and materials. Notable products such as aircraft, automobiles, computers, musical instruments, eyeglasses, firearms, jewelry, perfume and shoes are among those included. Components such as lasers, integrated circuits, metal cans, cartons, auto airbags, gears, jet engines, locks, electric motors, solar cells and superconductors are covered. This section also describes the manufacture of many foods including cereals, cheese, spices, and beverages (including alcoholic types), and materials such as plastics, metals and alloys, and important chemicals.
Quantity Price Model Description

$109.00 BK-MP
Handbook of Manufacturing Processes

Straightening Titanium Alloy Parts

Straightening Titanium Alloy Parts
Edward F. Rossman, Ph.D.
80 pages, Illustrated, 5 x 7
Published: July, 2007

OVERVIEW
Unlike any other book, this practical and proven guide will provide you with a foundation for determining causes and remedies for warpage in titanium alloy part fabrication. It discusses methods for straightening titanium alloy and describes criterion for selecting the most appropriate straightening process. You’ll never have to fight distortion or throw away warped titanium parts again!

FEATURES
* Discusses in detail the causes of warpage of titanium alloy airframe parts.
* Provides proven steps that can be taken to prevent warpage.
* Offers recipes for straightening titanium parts—straightening in a gas furnace, straightening in an electric furnace, straightening in a vacuum furnace, straightening cold, straightening by shot peening, straightening using blacksmithing techniques.

CONTENTS
Introduction
* Background
* Problem
* Purpose
* Scope and Limitations of Report
* Order of Reporting
Chapter 1: Causes and Prevention of Warpage
* Purpose
* Coverage and Limitations
* Three Areas of Stress
* Short-Term Solution (Straighten Part)
* Long-Term Solutions
* Summary
Chapter 2: Methods (Recipes) for Straightening
* Background and General Definitions
* Specific Purpose of this Chapter
* Order of Discussion
* Limitations
* Definitions and General Information
* Specific Methods and Processes for Straightening Parts (The Recipes)
* Summary
Chapter 3: Overall Summary
Index

Quantity Price Model Description

$25.75 BK-STAP
Straightening Titanium Alloy Parts