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V. C. Venkatesh
Faculty of Engineering & Technology
Multimedia University
Melaka, Malaysia
Sudin Izman
Faculty of Mechanical Engineering
Malaysian University of Technology
Johor Bahru, Malaysia
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DOI: 10.1036/0071548270
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To
My Family: Wife Gita, Sons—Dr. Vasisht Venkatesh & his Wife Shruti and Kaushik Venkatesh
& Grandson Rohan Venkatesh, all from Nevada, USA
—V.C. VENKATESH
TO
My Parents and Family
—IZMAN SUDIN
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This book owes its inspiration to the M Sc Programme in precision engineering initiated in GINTIC
Institute of Technology, Singapore by Cranfield University lecturers—Prof. P.A. McKeown,
Prof.J.Corbett, and Prof. W. Wills Moren during the author’s tenure at NTU, Singapore during
1993–97. This was further enhanced by the author’s CIRP and ASPE membership and his attendance
of their conferences. However, the main push was the purchase of Precitech’s ultra-precision turning
and grinding (UPTG) machine whose working needed to be understood. The need for high stiffness
brought about by hydrostatic and aerostatic bearings made the author work in this area while
introducing the course at the undergraduate level in NTU and later for seven years in UTM, Johor
Bahru, Malaysia. The author’s success with the publication of his first book Experimental techniques in
metal cutting in 1981, followed by a 2nd Edition in 1987 strengthened his resolve to write on precision
engineering.
This book is divided into eight chapters:
Chapter 1 is an introduction to precision engineering. It starts with McKeown’s scale
diagram fitting microtechnology and nanotechnology with some predictions. Accuracy and precision
have been clearly distinguished with the help of target shooting on a bull’s eye circle. Taniguchi’s
diagram of four classes of machining and his table of optical, mechanical and electronic products
are shown.
Chapter 2 deals with all precision cutting tool materials, with special emphasis on diamond
tools. There is an introduction to Miller indices with crystallographic planes of single crystal diamonds.
Their orientation for use as cutting tools especially for ultra-precision diamond turning is discussed.
CVD and PVD coatings are also highlighted.
Chapter 3 deals with the mechanics of materials cutting. Merchant’s mechanics of metal
cutting with all derivations is discussed, including the strain equation that was modified by Townend.
Since diamond turning now involves turning of non-metals like silicon and glass, this chapter uses
the phrase—materials cutting. The work of Scattergood and his colleagues is presented here.
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Chapter 4 is on advances in precision grinding and gives details of abrasives and their
classification when mounted on wheels. This chapter discusses ductile mode grinding and other well
known machine tools which combine ultra-precision turning and grinding options.
Chapter 5 on ultra-precision machine elements gives an introduction to elements that
constitute UPTG machines. Bed way materials and their shapes are described. Drive systems
comprising of nut and screw, friction and linear motor drives are discussed. There is also an
introduction to preferred numbers.
Chapter 6 discusses mostly hydrostatic bearings widely used in UPTG machines. However,
rolling elements are also highlighted since Toshiba has used them very successfully in their UPTG
machines. Hydrodynamic bearings are included in order to understand hybrid hydrostatic bearings
better.
Chapter 7 discusses gas lubricated bearings that are sometimes better known as aerostatic
bearings, which are used for spindles. Spindle design is discussed with examples. Gas bearings are
sometimes used for slide ways and their advantages, disadvantages and maintenance requirements
are highlighted in a table.
Chapter 8 is the final chapter and deals with MEMS (Microelectro-mechanical Systems).
Since silicon is the material that is used widely for MEMS its inclusion in this book is quite appropriate.
Bulk and surface micromachining and the LIGA process are discussed. The last part discusses clean
rooms and their design.
The late Dr. M.E. Merchant always emphasized that manufacturing is a source of wealth
generation. High-precision manufacturing is even more lucrative since it produces value added
products that use less material but more design and intricate manufacturing processes. Hopefully
this book is a small contribution to that goal.
It is hoped that the course in precision engineering will be introduced in many universities
particularly in India and SE Asia and hopefully world wide, and that this book will serve to help
lecturers and students alike in understanding this fascinating area, vital to developing countries.
V.C. VENKATESH
S. IZMAN
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I would like to thank industries/institutions that supported me in my research that resulted in many
pictures and information used in this book:
• Widia (India), Bangalore (now known as Kennametal Widia), which helped me in developing
the TiC-coated TiC tool. They were kind enough to furnish many cutting tools and micrographs.
• Central Manufacturing Technology Institute, Bangalore for lending their Machine Tools Design
Handbook, giving details of their clean rooms in the Precision Engineering Centre and their
Diamond Turning Machine Tool (India’s first).
• Kennametal Inc., Latrobe, USA for funding my work at Tennessee Technological University
(1993–1998) and furnishing me with the tools and micrographs while I was with the University
Technology Malaysia, Johor Bahru. I am also grateful for their help in developing the Bondless
Diamond Grinding Wheel.
• Lecturers from Cranfield University—Prof. McKeown, Prof. Corbett and Prof. Wills Moren,
who conducted the M Sc course in precision engineering at Nanyang Technological University,
Singapore and provided us with copious notes.
• Precitech Inc., Keene, NH, USA which I visited several times during my trips to the US. We
also bought their machine (Optimum 2800-X & Z axis) in 1996 while working with Nanyang
Technological University, Singapore. My special thanks go to Mr. Dennis Keating for the
personal discussions we had in Singapore, Malaysia and Keene, NH and also for being kind
enough to provide pictures of their machines and products.
• Moore Inc., Keene, NH, USA, which I visited several times during my trips to the US and
whose machine (Nanotech 250UPL-X & Z axis) was evaluated while I was with University
of Technology Malaysia and which will be installed shortly. My special thanks go to Mr. Len
Chaloux, CEO, for personal discussions and for providing me pictures of their machines and
products. My thanks also go to Mr. Gavin Chapman for discussions we had in Singapore and
Malaysia.
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