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Materials and Manufacturing Processes

ISSN: 1042-6914 (Print) 1532-2475 (Online) Journal homepage: http://www.tandfonline.com/loi/lmmp20

A review of: FUNDAMENTALS OF MACHINING


AND MACHINE TOOLS by Goeffrey Boothroyd and
Winston A. Knight Marcel Dekker, Inc., New York
Second edition, 542 pages, hardcover, 1989.
T.S. Srivatsan
To cite this article: T.S. Srivatsan (1990) A review of: FUNDAMENTALS OF MACHINING AND
MACHINE TOOLS by Goeffrey Boothroyd and Winston A. Knight Marcel Dekker, Inc., New York
Second edition, 542 pages, hardcover, 1989., Materials and Manufacturing Processes, 5:3,
485-487, DOI: 10.1080/10426919008953270
To link to this article: http://dx.doi.org/10.1080/10426919008953270

Published online: 02 May 2007.

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MATERIALS & MANUFACTURING PROCESSES, 5(3), 485-487 (1990)

BOOK REVIEW

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FUNDAMENTALS OF MACHINING AND MACHINE TOOLS


by
Goeffrey Boothroyd and Winston A Knight

Marcel Dekker, lnc., New York


Second edition, 542 pages, hardcover, 1989.
The contents of the book organized into fourteen chapters, covers selected topics
in machining and machine tools and is intended for those studying and teaching the
principles of metal machining. A significant portion of the book is based on a
previous text written by Goeffrey Boothroyd. Throughout this book emphasis is given
to the economics of machining operations and the design of components for
economic machining. However, little emphasis is given to the practical aspects of
machining. This would have rendered the book as a general reference to an
interested reader having an open mind to acquiring knowledge on machining
practices and principles rather than being restricted to the use of those having prior
knowledge and an understanding of the mechanics of machining.
The first nine chapters dwell on the concepts of metal cutting ranging from
machine motion and machining operations to the economics of metal cutting
operation, and including the mechanics of metal cutting, tool geometry and
nomenclature of cutting tools. Also well presented and discussed by the authors are
the closely associated factors: tool life and tool wear, cutting fluids and surface
roughness, lubrication, machine tool vibration, temperatures in metal cutting, and
chip control. The last five chapters provide an adequate insight into the shop floor
techniques such as Grinding, Types of Automation and Production, Computer Aided
Manufacturing, Design for Machining, and Non-Conventional Machining.
The classification of machine tools and machining operations is well presented
in Chapter 1. Based on this classification the various machines and the operations
that can be performed on them are examined and discussed. The fundamental
equations governing machine tool operation and machine tool characteristics are also
highlighted in this Chapter. The evolution, advancement, concepts and terminology
associated with metal cutting theory form the basis of discussion in Chapter 2. In this
chapter the authors provide a comprehensive insight into the key concepts of metal
cutting theory, and the mechanics and energy behind Chip formation. These aspects
are detailed from a mathematical perspective.

485
Copyright 1990 by Marcel Dekker, Inc.

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486

BOOK REVIEW

Temperature effects in metal cutting have been adequately covered in Chapter


3 with specific reference to heat generation and heat transfer, and the distribution
of temperature both in the tool and the workpiece. Tool wear directly affects the
quality of the end product, and hence, is an important factor that ought to be
considered during machining. Progressive tool wear, the various forms of wear in
metal cutting and the influence of wear on tool material and workpiece material are
detailed. Special attention is given to heat generation, heat transfer and distribution
of temperature both in the tool and the workpiece. The intrinsic factors governing
tool life, tool wear, coupled with the need for good cutting tool materials have been
well explained in Chapter 4.
The use of coolants and lubricants to minimize wear effects is presented in
Chapter 5. The application of cutting fluids and the role of surface roughness of the
workpiece in continued wear are well discussed by the authors. The various intricate
problems in machining are comprehensively reviewed, and the economics of metal
cutting operations is highlighted in Chapter 6. In this chapter, the essential
significance of selecting the right cutting speed-and tool feed for optimum machining
is emphasized. The factors essential for machining at maximum efficiency is well
presented and the authors conclude the chapter by emphasizing the economics of
having efficient tool material and tool designs.
Tool tip and associated tool geometry effects are as important as the material
used for the tool. A complete chapter is devoted to discussing the nomenclature of
cutting tools, wherein, the different systems of cutting tool nomenclature are
mentioned and the international standard system explained. The various aspects are
highlighted with specific reference to available types of tool material, the role of tool
life and contributions from machinability.
Chip and swarf removal is essential to ensure proper coolant flow and heat
dissipation during machining. Aspects pertaining to the importance of chip removal,
the various techniques available and used for chip removal, the methods for
predicting chip curvature and tool wear associated with chip breaking form the basis
of discussion in Chapter 8.
Vibration of machine tools is the central theme of discussion in the following
chapter. A comprehensive introduction of the various types of vibrations is provided
and technical aspects relating to methods for determining the frequency response loci
are also explained. The characteristics of dynamic acceptance tests for machine tools
and methods for improving machine tool stability are highlighted. Grinding which is
more than a finishing operation is presented in detail starting with the fundamental
terminology associated with grinding, composition of the grinding wheel designation
of grinding wheel, grinding wheel dressing and grinding wheel testing. Advanced
topics relating to energy requirements for grinding, grinding cycles, thermal effects
in grinding, need for cutting fluids in grinding and non-conventional grinding
operations form the basis of discussion in Chapter 10.

BOOK REVIEW

487

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Repeatability, reproducibility, reliability and quality are the key factors for
increasing productivity. This can be achieved byautomation. An insight into the types
of automation, types of production, the economics of automation, the intrinsic
characteristics of Numerically Controlled (NC) machines and Flexible Manufacturing
Systems (FMS) form the basis of discussion in Chapter 11.
More practical and current topics relating to the subject of machining, namely,
Computer Aided Manufacturing, Computer Aided Design for machining and NonConventional machining form the basis of coverage of the last three chapters. In the
chapter on computer aided manufacturing, the authors do well to highlight the scope
of the computer and the essential steps involved in implementing the computer.
Concepts of numerical controlled (NC) programming with specific reference to
programming language and standards are also well explained. The importance of
design with particular emphasis on simplifying machining and the associated benefits
are also discussed. The salient features of a variety of non-conventional machining
techniques ranging from ultrasonic machining to plasma arc cutting and including
abrasive jet machining, water-jet cutting, chemical machining, electrochemical
machining, electrolytic grinding, laser beam machining and wire electric discharge
machining are explained.
Each chapter concludes with a brief exercise and a list of references related to
the topic, The attractive feature of the book is that the mathematics is at low level
and it can be used as an ideal text for a course in Machining Principles and
Fundamentals for senior undergraduate students and graduate students in the fields
of materials science and engineering, metallurgy and mechanical engineering. It
would serve as a valuable addition to any library.
T.S. Srivatsan
Department of Mechanical Engineering
The University of Akron
Akron, Ohio 44325-3903

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