Metal removal processes - cutting and grinding in this book - are an integral part of a large number of manufacturing systems, either as the primary manufacturing process, or as an important part of preparing the tooling for other manufacturing processes. In recent years, industry and educational institutions have concentrated on the metal removal system, perhaps at the expense of the process. This book concentrates on metal removal processes, particularly on the modeling aspects that can either give a direct answer or suggest the general requirements as to how to control, improve or change a metal removal process. This modeling knowledge is more important with automated computer controlled systems than it has ever been before, because quantitative knowledge is needed to design and operate these systems. This senior undergraduate/graduate textbook is aimed at providing the quantitative knowledge, often times at an elementary level, for handling the technological aspects of setting up and operating a metal removal process and interpreting the experience of planning, operating and improving a metal removal process based on rule of thumb approaches.

1. Introduction.- 1.1 The Design Problem In Material Removal - Process Planning.- 1.2 Analysis of Material Removal for Process Planning.- 1.3 References.- 2. Metrology, Quality Control and Data Analysis.- 2.1 Metrology.- 2.2 Tolerancing.- 2.3 Quality Control.- 2.4 Experimental Design Methods for Empirical Data.- 2.5 References.- 2.6 Problems.- 3. Mechanics and Thermal Models for Machining.- 3.1 Classification of Chip Formation.- 3.2 Mechanics Models for Machining.- 3.3 Steady State Temperatures.- 3.4 References.- 3.5 Problems.- 4. Edge Materials, Wear and Fluids for Cutting and Grinding.- 4.1 Cutting Edge Materials.- 4.2 Cutting and Grinding Fluids.- 4.3 Wear of Cutting Edges.- 4.4 References.- 4.5 Problems.- 5. Practical Machining Processes.- 5.1 Common Factors and Analysis Methods.- 5.2 Turning and Facing.- 5.3 Face and End Milling.- 5.4 Drilling.- 5.5 References.- 5.6 Problems.- 6. Grinding Processes.- 6.1 Comparing Grinding With Cutting Processes.- 6.2 Terms and Specifications for the Grinding System.- 6.3 Kinematics of Grinding.- 6.4 Calculations for Planning a Grinding Cycle.- 6.5 References.- 6.6 Problems.- 7. Machining Economics and Optimization.- 7.1 Terms and Notation for Turning Optimization.- 7.2 Maximum Production Rate or Minimum Production Time.- 7.3 Minimum Unit Cost.- 7.4 Maximum Profit Rate.- 7.5 References.- 7.6 Problems.- 8. Modeling Machining Vibration for Stability Analysis.- 8.1 Classification of the Types of Vibration in Machining.- 8.2 Stability Analysis in Turning.- 8.3 Stability Analysis of Cylindrical Plunge Grinding.- 8.4 Some Practical Ways to Diagnose and Minimize Chatter.- 8.5 References.- 8.6 Problems.- Appendix Code for Simulation Examples.- 1 C Code for Example 5.3 Simulation of Face Milling.- 2 C Code for Example 8.1 Single Degree ofFreedom Stability Analysis for Turning.