This chapter presents the factors affecting machinability. It provides a detailed discussion on the machining of steel castings. These include microstructure effects, hardness and strength effects, turning, face milling and drilling, casting surface effects, and weld area effects. The chapter also presents an overview of machining practices.

This chapter covers the practical aspects of machining, particularly for turning, milling, drilling, and grinding operations. It begins with a discussion on machinability and its impact on quality and cost. It then describes the dimensional and surface finish tolerances that can be achieved through conventional machining methods, the mechanics of chip formation, the factors that affect tool wear, the selection and use of cutting fluids, and the determination of machining parameters based on force and power requirements. It also includes information on nontraditional machining processes such as electrical discharge, abrasive jet, and hydrodynamic machining, laser and electron beam machining, ultrasonic impact grinding, and electrical discharge wire cutting.

This chapter focuses on the metallurgical factors governing the machinability of stainless steels. It begins by describing the chemistry, cleanliness, structure, processing history, and the cross-section size of the stock of the different grades of stainless steel. This is followed by a general description of the machining behavior of the stainless steel families, namely ferritic, martensitic, austenitic, precipitation hardening, duplex, and super stainless steels. The beneficial effect of controlled inclusions is then discussed. The chapter ends with a section providing information on high-speed tool steel and carbide tooling, along with tool coatings and coolants applicable to stainless steel.

This chapter discusses the factors that influence the cost and complexity of machining titanium alloys. It explains how titanium compares to other metals in terms of cutting force and power requirements and how these forces, along with cutting speeds and the use of cutting fluids, affect tool life, surface finish, and part tolerances. The chapter also includes a brief review of nontraditional machining methods.

The qualities that make superalloys excellent engineering materials also make them difficult to machine. This chapter discusses the challenges involved in machining superalloys and the factors that determine machinability. It addresses material removal rates, cutting tool materials, tool life, and practical issues such as set up time, tool changes, and production scheduling. It describes several machining processes, including turning, boring, planing, trepanning, shaping, broaching, drilling, tapping, thread milling, and grinding. It also provides information on toolholders, fixturing, cutting and grinding fluids, and tooling modifications.

This appendix provides an extensive amount of data corresponding to titanium machining processes, including sawing, turning, drilling, reaming, tapping, broaching, face milling, end milling, slotting, surface grinding, and thermal cutting.

Machine vision is a means of simulating the image recognition and analysis capabilities of the human eye/brain system with electronic and electromechanical techniques. This chapter discusses four basic steps in the machine vision process, namely image formation, image preprocessing, image analysis, and image interpretation. Details of the processes involved, equipment used, and the factors to be considered are also presented. In addition, the applications of machine vision are discussed.

This chapter covers basic machining and assembly operations, with an emphasis on hole preparation for mechanical fasteners. It describes manual, power feed, and automated drilling techniques as well as reaming and countersinking. It discusses various types of fasteners, including rivets, pins, and bolts, along with selection factors and special considerations for composite joints. It also includes information on interference-fit and blind fasteners as well as trimming operations, general assembly considerations, and sealing and painting procedures.

The coordinate measuring machine (CMM) is used for three-dimensional inspection of both in-process and finished parts. This chapter provides a detailed account of the operating principles, measurement techniques, capabilities, and applications of CMMs. The types of CMMs are described. Vertical CMMs include cantilever-type, bridge-type, and gantry CMMs; horizontal CMMs, such as the horizontal-arm type, are also covered. The CMM application for geometric measurement, contour measurement, and specialized surface measurement are discussed.

Forging machines vary based on factors such as the rate at which energy is applied to the workpiece and the means by which it is controlled. Each type has distinct advantages and disadvantages, depending on lot size, workpiece complexity, dimensional tolerances, and the alloy being forged. This chapter covers the most common types of forging machines, explaining how they align with basic forging processes and corresponding force, energy, throughput, and accuracy requirements.

Prior to forging, it is often necessary to preform billet stock to achieve adequate material distribution. This chapter discusses the equipment used for such operations, including transverse rolling machines, electric upsetters, ring-rolling mills, horizontal presses, and rotary (orbital) and radial forging machines. It describes their basic operating principles as well as advantages and disadvantages.

Metal removal processes for gear manufacture can be grouped into two general categories: rough machining (or gear cutting) and finishing (or high-precision machining). This chapter discusses the processes involved in machining for bevel and other gears. The chapter describes the type of gear as the major variable and discusses the machining methods best suited to specific conditions. Next, the chapter provides information on gear cutter material and nominal speeds and feeds for gear hobbing. Further, it describes the cutting fluids recommended for gear cutting and presents a comparison of steels for gear cutting. The operating principles of computer numerical control and hobbing machines are also covered. This is followed by sections that discuss the processes involved in grinding, honing, and lapping of gears. Finally, the chapter provides information on the superfinishing of gears.