Reaming is a machining operation in which a rotary tool takes a light cut to improve the accuracy of the round hole and reduce the roughness of the hole surface. This article describes its process capabilities and provides information on workpiece material and hardness, as well as the machines used. Reamer materials and design, speed and feed, bushings and fixtures, and cutting fluids used are also discussed. The article outlines the factors to be considered while selecting a reamer. It also discusses the applications of the principle types of reamers, namely, straight-flute chucking, spiral-flute chucking, adjustable, end-cutting, shell, floating-blade, gun, and special-purpose reamers, with examples.

Magnesium is machined in low-volume production on small, manually operated machine tools and on large, specially built, completely automated transfer machines operating at high production rates. This article focuses on the factors that affect the machining of magnesium. It discusses chip formation and distortion due to thermal expansion, cold work, and clamping and provides information on magnesium-matrix composites. The article describes materials, design, and sharpness as factors for selection of tool for machining magnesium. It illustrates turning and boring, planing and shaping, broaching, drilling, reaming, counterboring, milling, sawing, and grinding operations performed on magnesium. Safety measures related to machining, handling of chips and fines, and fire extinguishing are also discussed.

Nickel-base alloys can be machined by techniques that are used for iron-base alloys. This article discusses the effects of distortion and microstructure on the machinability of nickel alloys. It tabulates the classification of nickel alloys based on machining characteristics. The article describes the machining operations performed on nickel alloys, such as turning, planing and shaping, broaching, reaming, drilling, tapping and threading, milling, sawing, and grinding. It provides information on the cutting fluids used in the machining of nickel alloys. The article also analyzes nontraditional machining methods that are suitable for shaping high-temperature, high-strength nickel alloys. These include electrochemical machining, electron beam machining, and laser beam machining.

This article begins with a discussion on the classification of aluminum alloys and the selection of alloy and temper based on machinability. It provides an overview of cutting force and power, tool design and material, and general machining conditions. In addition, the article discusses distortion and dimensional variation and machining problems during the machining of high-silicon aluminum alloy. It also provides information on tool design and material, speed and feed, and the cutting fluid used for various machining processes, namely, turning, boring, planing and shaping, broaching, reaming, tapping, milling, sawing, grinding, honing, and lapping. The article concludes with a discussion on drilling operations in automatic bar and chucking machines and drill presses.

The horsepower requirements to cut various metal alloys provide an indication of the relative ease and cost of machining, but several other important factors include cutting tool material, chip formation, cutting fluids, cutting tool wear, surface roughness, and surface integrity. This article reviews these general machining factors as well as specific cutting tool and cutting parameters for the six basic chip-forming processes of turning, shaping, milling, drilling, sawing, and broaching. Best practices for each of the six chip-forming processes are suggested for optimized machining of aluminum alloys. The article lists the inherent disadvantages of machining processes that involve compression/shear chip formation. It discusses the machining of aluminum metal-matrix composites and nontraditional machining of aluminum, such as abrasive jet, waterjet, electrodischarge, plasma arc, electrochemical, and chemical machining.

This article begins with a discussion on machinability ratings of copper and copper alloys and then describes the factors influencing the machinability ratings. It explains the effect of alloying elements, cold working, and cutting fluid on the machinability of copper and copper alloys. In addition, the article provides a comprehensive discussion on various machining techniques that are employed for machining of copper and copper alloys: turning, planing, drilling, reaming, tapping and threading, multiple operation machining, milling, slitting and circular sawing, power band sawing and power hacksawing, grinding, and honing.

This article focuses on the machining of reactive metals which refer collectively to the elements titanium, hafnium, and zirconium. It provides guidelines for machining titanium and titanium alloys and describes machining operations, such as turning, milling, drilling, tapping, reaming, grinding, and sawing, performed on titanium and its alloys. The article also provides information on electrochemical machining (ECM), chemical milling (CHM), and laser beam machining (LBM) for titanium and titanium alloys. Guidelines for machining zirconium alloys and hafnium are also provided. The article provides a short description of turning, milling, and drilling operations performed on zirconium alloys and hafnium. It also discusses health and safety considerations related to zirconium and hafnium.

This article provides a discussion on cutting tools, their materials and design; cutting fluids; and various aspects of machining operations of heat-resistant alloys, with several examples. Operations such as turning, planing and shaping, broaching, drilling, reaming, counterboring and spotfacing, tapping and thread milling, milling, sawing, and grinding are discussed. Nominal compositions of wrought heat-resistant alloys and nickel-base heat-resistant casting alloys, as well as compositions of cobalt-base heat-resistant casting, iron-base heat-resistant casting, and mechanically alloyed (oxide dispersion strengthened) products are also listed.

This article discusses the fundamentals of broaching, including broach tooth terminology, broach cutting action, and broach size. It describes two types of broaching machines: horizontal and vertical. The article illustrates three general categories of broaches: solid, shell, and insert-type. It tabulates feeds and speeds for broaching various steels with high-speed tool steels and carbide tools. The article also describes the advantages and limitations of broaching and provides a brief discussion on burnishing. The causes and prevention of broach breakage are also discussed. The article concludes with information on broach repair.

This article focuses on machines that are designed, constructed, and used for drilling. It provides information on the design, materials, selection, and classification of drill. The article describes drills that are specially designed for hard steel and other specific applications. A variety of drill point styles, such as single-angle points and reduced-rake points, are described. The article discusses the factors considered to obtain expected dimensional accuracy of holes. It explains the determination of the optimum speed and feed for drilling, which depends on the workpiece material, tool material, depth of hole, design of drill, rigidity of setup, tolerance, and cutting fluid. The article illustrates the effects of operating variables on drill life of hardened steel. The advantages, limitations, design considerations, insert configurations, and applications of indexable-insert drills are discussed. The article concludes with a discussion on the requirements to drill small holes that differ from those used in conventional drilling.

The machinability of stainless steels varies from low to very high, depending on the final choice of the alloy. This article discusses general material and machining characteristics of stainless steel. It briefly describes the classes of stainless steel, such as ferritic, martensitic, austenitic, duplex, and precipitation-hardenable alloys. The article examines the role of additives, such as sulfur, selenium, tellurium, lead, bismuth, and certain oxides, in improving machining performance. It provides ways to minimize difficulties involved in the traditional machining of stainless steels. The article describes turning, drilling, tapping, milling, broaching, reaming, and grinding operations on stainless steel. It concludes with information on some of the nontraditional machining techniques, including abrasive jet machining, abrasive waterjet machining electrochemical machining, electron beam machining, and plasma arc machining.

This article describes the selection of tool steels on the basis of specific product applications. It contains tables that list nominal speeds and feeds for the machining of various tool steels. The machining processes include turning, boring, broaching, drilling, reaming, tapping, milling, and sawing. The article explains the machining of the following tool steels: water hardening; types A, D and O cold-work; hot work; high speed, low-alloy special-purpose; and low-carbon mold. It details the machining of tool steel gears. The article also discusses the grinding of tool steels based on steel classification and the effects of steel composition and hardness on grindability. It reviews the types of grinding, namely, surface grinding, cylindrical grinding, centerless grinding, internal grinding, thread grinding, flute grinding, and low-stress grinding. Grinding of types-A, D, F, L, O, P, S and W steels, hot-work steels, and high speed steels, is also detailed.

This article discusses the factors influencing cast iron machining and selection of cutting fluid and cutting tool materials. It presents a comparison of machinability of different types of cast iron, namely, gray cast iron, ductile cast iron, and malleable cast iron. In addition, the article provides an overview of different methods used in the machining of cast iron, namely, turning, boring, broaching, planing and shaping, drilling, reaming, counterboring and spotfacing, tapping, milling, grinding, and honing and lapping. Nominal speeds and feeds for the machining of cast iron with single-point and box tools, ceramic tools, high-speed steel, and carbide tools are also tabulated.

Rust-preventive compounds are removable coatings used for the protection of the surfaces of iron, steel, coated or galvanized products, and other alloys. This article describes the basic parts of rust-preventive compounds, namely, carrier, film former, polar materials, and specialty additives. It explains types of rust-preventive compounds, including dry films and water-based dry films. The article also discusses the methods of application of various compounds, such as petrolatum compounds and emulsion compounds. It contains tables that provide information on the characteristics, applications, and physical properties of rust-preventive materials covered by military specifications. Finally, the article describes the various considerations and parameters for selecting rust-preventive materials.

Metals and alloy powders are used in welding, hardfacing, brazing, and soldering applications, which include hardface coatings, the manufacturing of welding stick electrodes and flux-cored wires, and additives in brazing pastes or creams. This article reviews these applications and the specific powder properties and characteristics they require.

This article is a compilation of terms related to surface engineering of irons, steels, and nonferrous metals.

This article focuses on the use of indium and bismuth in low-melting-temperature solders and fusible alloys. It describes how the two elements typically occur in nature and how they are recovered and processed for commercial use. It also provides information on designations, classification, composition, properties (including temperatures ranges), and some of the other ways in which indium and bismuth alloys are used.