Metal Cutting Theory and Practice Second Edition

David A. Stephenson John S. Agapiou

L,jfi) Taylor & Francis VV^

J

Taylor Si Francis Group Boca Raton London New York

A CRC title, part of the Taylor & Francis imprint, a member of the Taylor & Francis Group, the academic division of T&F Informa pic.

Contents 1. Introduction 1.1 Scope of the Subject 1.2 Historical Development 1.3 Types of Production References

1 1 1 14 14

2. Metal Cutting Operations 2.1 Introduction 2.2 Turning 2.3 Boring 2.4 Drilling 2.5 Reaming 2.6 Milling 2.7 Planing and Shaping 2.8 Broaching 2.9 Tapping and Threading 2.10 Grinding and Related Abrasive Processes 2.11 Roller Burnishing 2.12 Deburring 2.13 Examples 2.14 Problems References

17 17 17 20 21 27 28 33 33 35 44 52 54 54 66 68

3. Machine Tools 3.1 Introduction 3.2 Production Machine Tools 3.3 CNC Machine Tools and Cellular Manufacturing Systems 3.4 Machine Tool Structures 3.5 Slides and Guideways 3.6 Axis Drives 3.7 Spindles 3.8 Coolant Systems 3.9 Tool Changing Systems 3.10 Examples References

71 71 72 77 91 102 106 Ill 126 126 129 133

4. Cutting Tools 4.1 Introduction 4.2 Cutting Tool Materials

141 141 141

xiv

Contents

4.3 Tool Coatings 4.4 Basic Types of Cutting Tools 4.5 Turning Tools 4.6 Boring Tools 4.7 Milling Tools 4.8 Drilling Tools 4.9 Reamers 4.10 Threading Tools 4.11 Grinding Wheels 4.12 Microsizing and Honing Tools 4.13 Burnishing Tools 4.14 Examples 4.15 Problems References

155 162 163 173 179 192 223 228 236 243 245 245 258 258

5.

Toolholders and Workholders 5.1 Introduction 5.2 Toolholding Systems 5.3 Toolholder-Spindle Connection 5.4 Cutting Tool Clamping Systems 5.5 Balancing Requirements for Toolholders 5.6 Fixtures 5.7 Examples 5.8 Problems References

265 265 265 270 313 341 347 353 366 366

6.

Mechanics of Cutting 6.1 Introduction 6.2 Measurement of Cutting Forces and Chip Thickness 6.3 Force Components 6.4 Empirical Force Models 6.5 Specific Cutting Power 6.6 Chip Formation and Primary Plastic Deformation 6.7 Tool-Chip Friction and Secondary Deformation 6.8 Shear Plane and Slip-Line Theories for Continuous Chip Formation 6.9 Shear Plane Models for Oblique Cutting 6.10 Shear Zone Models 6.11 Minimum Work and Uniqueness Assumptions 6.12 Finite Element Models 6.13 Discontinuous Chip Formation 6.14 Built-up Edge Formation 6.15 Examples 6.16 Problems References

371 371 371 374 378 380 382 389 394 398 399 403 404 408 411 413 415 416

7.

Cutting Temperatures 7.1 Introduction 7.2 Measurement of Cutting Temperatures 7.3 Factors Affecting Cutting Temperatures

425 425 425 432

Contents

xv

7.4 Analytical Models for Steady-State Temperatures 7.5 Finite Element and Other Numerical Models 7.6 Temperatures in Interrupted Cutting .'-• 7.7 Temperatures in Drilling 7.8 Thermal Expansion 7.9 Examples 7.10 Problems References

434 437 441 444 446 448 451 451

8. Machining Process Analysis 8.1 Introduction 8.2 Turning 8.3 Boring 8.4 Milling 8.5 Drilling 8.6 Force Equations and Baseline Data 8.7 Process Simulation Application Examples 8.8 Finite Element Analysis for Clamping, Fixturing, and Workpiece Distortion Applications 8.9 Finite Element Application Examples 8.10 Examples 8.11 Problems References

459 459 460 462 465 470 478 482

9. Tool Wear and Tool Life : 9.1 Introduction 9.2 Types of Tool Wear 9.3 Measurement of Tool Wear 9.4 Tool Wear Mechanisms 9.5 Tool Wear — Material Considerations 9.6 Tool Life Testing 9.7 Tool Life Equations 9.8 Prediction of Tool Wear Rates 9.9 Tool Fracture and Edge Chipping 9.10 Drill Wear and Breakage 9.11 Thermal Cracking and Tool Fracture in Milling 9.12 Tool Wear Monitoring 9.13 Examples 9.14 Problems References

503 503 504 508 512 514 521 522 525 528 530 534 537 537 543 545

10. Surface Finish and Integrity 10.1 Introduction 10.2 Measurement of Surface Finish 10.3 Surface Finish in Turning and Boring 10.4 Surface Finish in Milling 10.5 Surface Finish in Drilling and Reaming 10.6 Surface Finish in Grinding 10.7 Residual Stresses in Machined Surfaces

484 489 493 499 499

551 551 552 558 562 565 566 568

xvi

Contents

10.8 White Layer Formation 10.9 Surface Burn in Grinding 10.10 Examples 10.11 Problems References

569 570 571 573 574

11.

Machinability of Materials 11.1 Introduction 11.2 Machiikability Criteria, Tests, and Indices 11.3 Chip Control 11.4 Burr Formation and Control 11.5 Machinability of Engineering Materials References

577 577 578 582 588 591 611

12.

Machining Dynamics 12.1 Introduction 12.2 Vibration Analysis Methods 12.3 Vibration of Discrete (Lumped Mass) Systems 12.4 Types of Machine Tool Vibration 12.5 Forced Vibration 12.6 Self-Excited Vibrations (Chatter) 12.7 Chatter Prediction 12.8 Vibration Control 12.9 Active Vibration Control 12.10 Examples 12.11 Problems References

617 617 617 618 630 632 636 653 658 662 669 691 697

13.

Machining Economics and Optimization 13.1 Introduction 13.2 Role of a Computerized Optimization System 13.3 Economic Considerations 13.4 Optimization of Machining Systems — Basic Factors 13.5 Optimization of Machining Conditions 13.6 Formulation of the Optimization Problem 13.7 Optimization Techniques 13.8 Examples 13.9 Problems References

705 705 707 708 710 711 712 719 741 758 760

14.

Cutting Fluids 14.1 Introduction 14.2 Types of Cutting Fluids 14.3 Coolant Application 14.4 Filtering 14.5 Condition Monitoring and Waste Treatment 14.6 Health and Safety Concerns 14.7 Dry and Near-Dry Machining Methods

767 767 768 771 773 778 779 781

Contents

xvii

14.8 Test Procedure for Cutting Fluid Evaluation References

783 783

15. High Throughput and Agile Machining 15.1 Introduction 15.2 High Throughput Machining 15.3 Agile Machining Systems 15.4 Tooling and Fixturing 15.5 Materials Handling Systems References

787 787 787 789 791 800 802

16. Design for Machining 16.1 Introduction 16.2 Machining Costs 16.3 General Design for Machining Rules 16.4 Special Considerations for Specific Types of Equipment and Operations 16.5 CAPP and DFM Programs 16.6 Part Quality Modeling 16.7 Examples References

805 805 805 806

Index

833

•.

813 817 819 822 831