Precision Engineering

✍ Scribed by V. C. Venkatesh, Sudin Izman

• Publisher: McGraw-Hill Professional
• Year: 2008
• Tongue: English
• Leaves: 435
• Edition: 1
• Category: Library

✦ Synopsis

The Latest Techniques of Ultra-Precise Manufacturing for Creating Mechanical, Electronic, and Optical Products

Precision Engineering gives expert guidance on the application of manufacturing to micro and nano levels, using state-of-the-art miniaturization technology. The book fully explores these new in-demand techniques, providing clear explanations of precision engineering fundamentals, the theory and design of precision machines, and the mechanics of ultra-precise machining.

Filled with over 200 skills-building illustrations, this vital engineering resource examines topics ranging from atomic bit processes for manufacturing and atomic force…to scanning and electronic and optical microscopy. You will find timely information on the tool materials for precision machining…the mechanics of materials cutting…advances in precision grinding…ultra-precision machine elements…rolling element, hydrodynamic, and hydrostatic bearings…gas lubricated bearings… microelectromechanical systems (MEMS)…and much more. Presenting practical know-how on everything required to create actual products, Precision Engineering features:

• A full account of tool materials for precision engineering
• The latest methods of precision grinding
• Detailed analysis of ultra-precise machine elements
• In-depth coverage of microelectromechanical systems (MEMS)

Inside This Cutting-Edge Guide to Precision Engineering Methods

• Tool Materials for Precision Machining • Mechanics of Materials Cutting • Advances in Precision Grinding • Ultra-Precision Machine Elements • Rolling Element, Hydrodynamic, and Hydrostatic Bearings • Gas Lubricated Bearings • Microelectromechanical Systems (MEMS)

✦ Table of Contents

Contents......Page 12
Preface......Page 8
Acknowledgements......Page 10
1.1 Introduction to Precision Engineering......Page 18
1.2 The Difference between Accuracy and Precision......Page 19
1.4 Developmental Perspective of Machining Precision......Page 23
1.6 Normal Machining......Page 25
1.6.1 Gear Manufacture by Normal Machining......Page 29
1.7.1 Machining of Integrated Circuit Chips on a CNC Milling Machine for Failure Analysis......Page 32
1.7.2 Precision Manufacture of Spherical and Aspheric Surfaces on Plastics and Glass......Page 34
1.8 High-precision Machining......Page 39
1.9 Ultra-precision Machining......Page 42
1.9.1 Ultra-precision Processes and Nanotechnology......Page 44
1.11 References......Page 47
1.12 Review Questions......Page 48
2.1 Introduction......Page 50
2.2.1 Laminated Carbides......Page 53
2.2.2 CVD Coated Carbides......Page 54
2.2.4 Coating of the Second Generation of TiC (Cermets)......Page 58
2.2.5 PVD Coated Carbides......Page 60
2.3 Ceramics......Page 62
2.3.1 Hot-pressed Ceramics......Page 64
2.3.2 Silicon Nitride Ceramics......Page 65
2.4 Diamonds......Page 66
2.4.1 Crystallographic Planes......Page 67
2.4.3 Synthetic Diamonds......Page 73
2.4.4 Polycrystalline Diamond (PCD)......Page 75
2.4.5 Single-crystal Diamond (SPSCD)......Page 76
2.4.6 Diamond Coated Tools......Page 77
2.4.7 Design of Diamond Tools......Page 82
2.5 Cubic Boron Nitride (CBN)......Page 84
2.5.1 Coated CBN......Page 90
2.6 Tool and Work Material Compatibility......Page 92
2.7 References......Page 94
2.8 Review Questions......Page 96
3.1 Introduction......Page 97
3.2 An Overview of the Turning Operation and Tool Signature......Page 98
3.2.1 Single-point Cutting Tools......Page 99
3.3 Mechanics of Conventional Metal Cutting......Page 102
3.3.2 Chip Formation and Cutting Forces in Metal Cutting......Page 103
3.3.3 Merchant’s Theory......Page 107
3.3.4 Merchant’s Shear Angle......Page 108
3.3.5 Merchant’s Modified Shear Angle (Bridgman’s Theory)......Page 110
3.3.6 Merchant’s Strain Equation......Page 111
3.3.8 A Graphical Method to Construct Merchant’s Circle......Page 113
3.3.9 Mechanics of Oblique Cutting......Page 116
3.4.1 Basic Mechanics of Grinding—Material Removal Mechanism......Page 125
3.4.2 Grit Depth of Cut......Page 127
3.4.3 Specific Energy......Page 131
3.4.4 Temperature During Grinding......Page 133
3.4.5 Grinding Wheel Wear......Page 134
3.4.6 Truing and Dressing of Grinding Wheels......Page 135
3.5 Material Removal Mechanisms in Brittle Materials......Page 137
3.5.1 Ductile Mode Machining of Hard and Brittle Materials......Page 141
3.5.2 Models for Ductile Mode Machining of Brittle Materials......Page 143
3.6 References......Page 155
3.7 Review Questions......Page 157
4.1 Introduction......Page 159
4.2.1 Bonding Materials......Page 160
4.2.2 Abrasive Types......Page 161
4.2.3 Grit Size......Page 162
4.2.6 Concentration......Page 163
4.2.7 Design and Selection of the Grinding Wheel......Page 165
4.2.8 Mounted Wheels......Page 167
4.2.9 Bondless Diamond Grinding Wheel......Page 168
4.3 Conventional Grinding......Page 172
4.4.1 Jig Grinding for IC Chip Manufacturing......Page 176
4.4.2 Precision Grinding with Electrolytic In-process Dressing (ELID)......Page 180
4.4.3 Various Methods for Generating an Aspheric Surface......Page 182
4.5.1 Various Ultra-precision Machines and Their Development......Page 191
4.5.2 Some Applications of Ultra-precision Machining......Page 197
4.6 References......Page 199
4.7 Review Questions......Page 203
5.1 Introduction......Page 204
5.2 Guideways......Page 209
5.3.1 Nut and Screw Transmission......Page 214
5.3.2 Friction Drive......Page 218
5.3.3 Linear Motor Drive......Page 221
5.4 Spindle Drive......Page 229
5.5 Preferred Numbers......Page 230
5.7 Review Questions......Page 233
6.1 Introduction......Page 236
6.2.1 Principle of Rolling Element Bearings......Page 237
6.2.3 Classification of Rolling Element Bearings......Page 238
6.2.4 Application of Rolling Element Bearings......Page 242
6.2.5 Selection of Rolling Element Bearings......Page 243
6.2.6 Fitting of Rolling Element Bearings......Page 244
6.2.7 Bearing Life......Page 248
6.3 Lubricated Sliding Bearings......Page 253
6.3.2 Principle of Lubrication......Page 254
6.3.3 Principle of Hydrodynamic Bearings......Page 257
6.3.4 Comparison and Selection Between Rolling and Sliding Bearings......Page 258
6.3.5 Hydrodynamic Thrust Bearings......Page 262
6.3.6 Application of Hydrodynamic Bearings......Page 263
6.3.7 Mathematical Approximation of Hydrodynamic Bearings......Page 267
6.4 Hydrostatic Bearings......Page 270
6.4.2 Construction of Hydrostatic Bearings......Page 271
6.4.3 Classification of Hydrostatic Bearings......Page 274
6.4.4 Operation of a Hydrostatic Bearing System......Page 276
6.4.5 Advantages and Disadvantages of Hydrostatic Bearings......Page 278
6.4.6 Application of Hydrostatic Bearings......Page 279
6.4.7 Mathematical Approximation of Hydrostatic Bearings......Page 281
6.4.8 Design of Hydrostatic Bearings......Page 285
6.5 Hybrid Fluid Bearings......Page 298
6.6 References......Page 299
6.7 Review Questions......Page 300
7.1 Introduction......Page 304
7.2 Aerodynamic Bearings......Page 305
7.3.1 Principle of Aerostatic Bearings......Page 306
7.3.2 Construction of Aerostatic Bearings......Page 308
7.3.3 Classification of Aerostatic Bearings......Page 310
7.3.4 Operation of Aerostatic Bearing Systems......Page 313
7.3.5 Advantages and Disadvantages of Aerostatic Bearings......Page 315
7.3.6 Application and Principles of Aerostatic Bearings......Page 318
7.3.7 Aerostatic Spindles......Page 324
7.3.8 Mathematical Approximation of Aerostatic Bearings......Page 327
7.3.9 Theory of Aerostatic Lubrication......Page 329
7.3.10 Design of Aerostatic Journal Bearings......Page 335
7.3.11 Thrust Bearings......Page 354
7.4 Hybrid Gas Bearings......Page 362
7.5 Comparison of Bearing Systems......Page 366
7.6 Material Selection for Bearings......Page 373
7.7 References......Page 378
7.8 Review Questions......Page 379
8.1 Introduction......Page 383
8.2 Advances in Microelectronics......Page 384
8.3 Characteristics and Principles of MEMS......Page 385
8.4 Design of MEMS......Page 389
8.5 Application of MEMS......Page 396
8.5.1 Application of MEMS in Automobiles......Page 397
8.5.2 Application of MEMS in the Health-care Industry......Page 401
8.5.3 Application of MEMS in Defence......Page 402
8.5.5 Application of MEMS in Industrial Products......Page 403
8.6 Materials for MEMS......Page 404
8.7 MEMS Fabrication and Micromanufacturing Processes......Page 406
8.7.1 Bulk Micromachining......Page 407
8.7.2 Surface Micromachining......Page 410
8.7.3 LIGA Process......Page 412
8.8 MEMS and Microsystem Packaging......Page 414
8.9 Future of MEMS......Page 415
8.10 Clean Rooms......Page 416
8.10.1 Effects of Various Parameters......Page 417
8.10.2 The Design and Construction of Clean Rooms......Page 421
8.11 References......Page 423
8.12 Review Questions......Page 424
C......Page 425
H......Page 426
M......Page 427
P......Page 428
T......Page 429
Z......Page 430
C......Page 431
G......Page 432
M......Page 433
T......Page 434
Z......Page 435