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Precision Engineering
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3 McKeown, PA, High precision manufacturing in an advanced industrial economy, James Clayton Lecture, IMechE, 23rd April 1986 4 Fang, FZ and Venkatesh, VC, Diamond cutting of silicon with nanometric finish, Annals of the CIRP, 1998, Vol 47/1/, 45 49 5 Taniguchi, N, Current status in and future trends of ultra precision machining and ultra-fine processing, Annals of the CIRP, 1983, Vol 32, No 2, 573 582 6 Kalpakjian, S and Schmid, SR, Manufacturing Processes for Engineering Materials Prentice Hall, 1995 7 DeGarmo, EP, Black, JT and Kohsher, RA, Materials and Processes in Manufacturing, 6th ed, Macmillan Publishing Company, New York, 1964 8 Lindberg, RA, Processes and Materials of Manufacture, Allyn and Bacon Inc, USA, 1964 9 Konneh, M, An Experimental Investigation of Partial-Ductile Mode Grinding of Silicon PhD Thesis, Universiti Teknologi Malaysia, 2002 10 Mon, TT, Chemical-Mechanical Polishing of Optical Glass Subjected to Partial Ductile Grinding, Masters Thesis, Universiti Teknologi Malaysia, 2002 11 Izman, S, Machining of BK-7 Glass Subjected to Partial-Ductile Regime Grinding, PhD Thesis, Universiti Teknologi Malaysia, 2003 12 Venkatesh, VC, Precision manufacture of spherical and aspherical surfaces on plastics, glass, silicon and germanium, Current Science, Indian Academy of Sciences, 2003, Vol 84, No 9, 1211 1219 13 Venkatesh, VC and Tan, CP, The generation of aspheric surfaces on thermal imaging materials on a 4-axis CNC machining centre, Proceedings of ASPE Annual Meeting, Rochester, NY, 1990, 23 26 14 Horne, DF, Optical Reduction Technology Adam Hilger, Bristol, 2nd Ed, 1983 15 Kennedy, CW, Hoffman, EG and Bond, SD, Inspection and Gauging, 6th Ed, Industrial Press, USA, 1987 16 Venkatesh, VC, Inasaki, I, Toenshof, HK, Nakagawa, T and Marinescu, ID, Observations on polishing and ultra precision machining of semiconductor substrate materials, Annals of the CIRP, 1995, Vol 44/2/1995, 611 618 17 Bradley, IA, A History of Machine Tools, Model and Allied Publications Ltd, UK, 1972 18 Donaldson, RD, Patterson, S, Design and construction of a large vertical-axis diamond turning machine, SPIE s 27th Ann Int Tech Instrument Display, August 1983, 21 26 19 Bryan, JB, Design and construction of an ultra precision 84 inch diamond turning machine Precision Engineering, 1979, Vol 1, No 1, pp 13 17 20 Sagar, P, Temperature variations can crush accuracy, SME Magazine-Machine tool Basics, March 2001, 80 88 21 Cooling System Catalogue (in Japanese), BIG DAISHOWA, Vol 3, 148 22 Jackson, MJ, Microfabrication and Nanomanufacturing, Taylor and Francis, USA, 2006
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112 REVIEW QUESTIONS
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11 Explain with sketches the difference between accuracy and precision 12 (a) Discuss the achievable machining accuracy for normal, precision, high-precision and ultra-precision machining (b) Highlight some mechanical, electronic, and optical components, their tolerances and their machining aspects (c) Describe with sketches one component from each one of the above categories
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Precision Engineering
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13 Figure 15 on page 7 shows the development of overall machining precision starting from the early 1900s State the machining accuracy achieved in 2000 for: (a) Normal machining (b) Precision machining (c) High-precision machining (d) Ultra-precision machining 14 Referring to the Modified Taniguchi Chart, when will the development of the machining process in Singapore be anticipated
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TOOL MATERIALS FOR PRECISION MACHINING
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21 INTRODUCTION
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Cutting tool materials are required to have several properties that enhance the efficiency of the material removal process The main requirements for cutting tool materials are as follows: High hot hardness High wear resistance High-temperature physical and chemical stability Toughness or high resistance to brittle fracture Figure 21 illustrates the major classes of tool materials A comparison between hot hardness, wear resistance and toughness is shown in Table 21 It indicates that single-crystal diamond which is widely used for ultra-precision applications has the highest hot hardness and wear resistance, but it lacks toughness in terms of which it is quite surprising that this earliest tool material still holds an edge over other materials Carbon steels and high-speed steels are of excellent toughness A clearer picture can be obtained from Table 22 that indicates the relative values of several properties for each of the cutting tool materials Of the major classes of tool materials, carbon steels, high-speed steels and cast alloys are seldom used in precision applications and are therefore not discussed in great detail Carbon steel is the earliest tool material that was widely used for making drills, taps, reamers, and broaches [1] The use of carbon steel is restricted to low cutting speeds and temperatures [2] Steel containing 08 14% carbon is quenched at 750 800 C (in brine or water) and tempered at 180-200 C to obtain a martensitic structure and a high cold hardness (Rc = 65) [3] Low-alloy and medium-alloy steels, with a longer tool life, were developed later for similar applications
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