High-speed Machining BERT P. ERDEL

Machining Technology Association of SME

Dearborn, Michigan

prepages.pmd

3

4/14/03, 12:09 PM

Copyright © 2003 by the Society of Manufacturing Engineers 987654321 All rights reserved, including those of translation. This book, or parts thereof, may not be reproduced by any means, including photocopying, recording or microfilming, or by any information storage and retrieval system, without permission in writing of the copyright owners. No liability is assumed by the publisher with respect to use of information contained herein. While every precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions. Publication of any data in this book does not constitute a recommendation or endorsement of any patent, proprietary right, or product that may be involved. Library of Congress Catalog Card Number: 2003103270 International Standard Book Number: 0-87263-649-6 Additional copies may be obtained by contacting: Society of Manufacturing Engineers Customer Service One SME Drive, P.O. Box 930 Dearborn, Michigan 48121 1-800-733-4763 www.sme.org SME staff who participated in producing this book: Phil Mitchell, Senior Editor Rosemary Csizmadia, Production Supervisor Frances Kania, Production Assistant Kathye Quirk, Graphic Designer/Cover Design Jon Newberg, Production Editor Cover photo courtesy Mazak Corp. Printed in the United States of America

prepages.pmd

4

4/14/03, 12:09 PM

ABOUT SME The Society of Manufacturing Engineers (SME) is the world’s leading professional society supporting lifelong manufacturing education. Through our member programs, publications, expositions and professional development resources, SME promotes an increased awareness of manufacturing engineering and helps keep manufacturing professionals up to date on leading trends and technologies. Headquartered in Dearborn, Michigan, SME influences more than half a million manufacturing engineers, executives, and practitioners annually. The Society has members in 70 countries and is supported by a network of hundreds of chapters worldwide.

ABOUT MTA/SME The Machining Technology Association of SME (MTA/SME) provides a forum for exploring the practical application of innovations in material-removal processes, such as turning, milling, and grinding, and the machines and tooling used in these processes. MTA/SME members represent a cross-section of disciplines, including manufacturing, tool, process, mechanical, and industrial engineers, production and plant managers, and researchers and educators. They are interested in the latest developments in CNC machine tools, cutting-tool materials, tool geometry, workholding devices, and cutting fluids. Typical industries served include automotive, aerospace, defense, appliance, and other general metalworking manufacturing sectors.

prepages.pmd

5

4/14/03, 12:09 PM

To My Beloved Children Christoph, Gillian, and Wolfgang

prepages.pmd

7

4/14/03, 12:09 PM

Acknowledgments

This book would not have been possible without the extraordinary support of my staff and team who have supported me over the years on our exceptional path of success. To all of you I am deeply indebted. My special thanks go to Dr. Michael Kaiser for his technical assistance and expertise; to Susan Ephraim for her patience and diligence in formatting; and to Dave Itterly for the outstanding artwork. I would also like to thank Jerry Scherer at GE Fanuc Automation for reviewing certain chapters of this book. I express my deep gratitude to the many people who have inspired me over the years. They have been instrumental in writing this book in so many ways.

prepages.pmd

9

4/14/03, 12:09 PM

Chapter

Table of Contents Preface ........................................................................................... xv 1 Introduction ................................................................................ 1 Advanced Machining Processes .......................................................2 A New Era ........................................................................................3

2 The Determinants of High-speed/ High-performance Machining ..................................................... 5 Weight, Materials, Machine Tools ......................................................6 Simple Processes and Systems ........................................................9 Fast Machining, Response Time, and Throughput ...........................11 Smart Machines, Tools, and Processes ..........................................14

3 Characteristics of High-speed Machining ................................. 21 Machining Parameters ....................................................................21

4 Machine-tool Technology .......................................................... 25 Manufacturing and Multi-task Machining Systems ..........................25 High-speed/High-velocity Machining ...............................................29 Support Technology .......................................................................38

5 Advanced Cutting Tools ............................................................ 45 Trends ............................................................................................46 Cutting-tool Materials .....................................................................48 Cutting-tool Design .........................................................................66 Tool Guidance and Stability .............................................................70 Chip Control ...................................................................................75 Burr Control ...................................................................................76

High-speed Machining

prepages.pmd

xi

11

4/14/03, 12:09 PM

Chapter Table of Contents

Tooling Adjustments .......................................................................77 Stringent Finish Requirements ........................................................81 Cost and Quality .............................................................................85 Total Quality Management ...............................................................87 Intelligent Tooling ............................................................................92

6 Precision Tooling Interface ....................................................... 97 Connection and Interface ................................................................98 Tool Clamping ..............................................................................100 Balancing .....................................................................................110 Runout .........................................................................................111

7 Manufacturing Enablers ......................................................... 115 Third-party Supply .......................................................................115 Change of Business Paradigms ....................................................116 Specifying the Best Machining Processes .....................................123 Tool Management .........................................................................128

8 Dry and Near-dry Machining .................................................. 133 Environmental Impact ...................................................................133 Dry Machining .............................................................................134 Near-dry Machining ......................................................................139 Reducing Coolant Use ..................................................................146 Conclusion ...................................................................................149

9 The Transition to High-performance Machining...................... 151 Technology Forecasting ................................................................151 Process-oriented Manufacturing ...................................................155 Concurrent Engineering ................................................................157 Concurrent Manufacturing ............................................................162

10 The Move to High-performance Machining ............................ 169 Case Studies ................................................................................169 Simplifying Machining Operations .................................................171 New Cutting-tool Technology ........................................................176 High-speed Machining ..................................................................177

xii

prepages.pmd

High-speed Machining

12

4/14/03, 12:09 PM

Table of Contents Chapter

One-pass Machining ....................................................................192 Combination Tooling .....................................................................195 Interpolation Tools ........................................................................199 One-step Thread Milling ................................................................201 Hybrid Processes .........................................................................201 Conclusion ...................................................................................208

11 Practical Applications ............................................................. 211 Guided Fine-boring .......................................................................211 Precision Hard Machining .............................................................213 Machining Compacted Graphite Iron .............................................214 Interpolation Tools ........................................................................216 Precision Roughing ......................................................................216 Advanced Milling Operations ........................................................221 Actuating Tool Systems ................................................................223 Crankshaft- and Camshaft-bore Machining ...................................226 Helically Fluted Milling ..................................................................227 Machining with Multi-cut tools ......................................................229

12 Trends and Outlook ................................................................. 233 Materials ......................................................................................233 Machine Technology .....................................................................233 Tooling Technology .......................................................................234 Processes ....................................................................................234

Bibliography ................................................................................ 237 Index............................................................................................ 241

High-speed Machining

prepages.pmd

xiii

13

4/14/03, 12:09 PM

Chapter

Preface

Manufacturers are intertwined in a global network of seemingly endless streams of information and product varieties, and as life picks up pace, producers and consumers turn to scientists and engineers for technology-based innovation. The question is whether continued innovation can be sustained enough to maintain manufacturing progress, and whether manufacturing companies have the acumen to adopt new strategies, systems, and processes. The growing demands of customers are transforming the way products are manufactured. This book is written to show how high-speed machining technology and innovation can be used for the advantage of all industrial manufacturing. It is possible to economically produce exceptional quality products with high productivity. However, it can be done only if companies take a holistic approach. They must assemble the collective knowledge of all facets of the enterprise and apply it to current processes and technologies for their continuous improvement. Manufacturing entities can no longer afford to just look at machines and tools for producing products. Manufacturing paradigms will continue to gravitate toward agility, rapid product output, shorter product development cycles, and the ability to adjust to erratic market changes, as well as to a company’s own innovative abilities and corporate knowledge. This book will show how to secure high performance on the production floor and explain its benefits. Moreover, it will show that manufacturing has not yet reached the point of diminishing returns. If companies embrace technological innovation, the challenges ahead are exciting opportunities in the world of manufacturing.

High-speed Machining

prepages.pmd

xv

15

4/14/03, 12:09 PM

To order call 1-800-733-4763 or visit www.sme.org/store and search on book title