Metal Cutting Theory and Practice

Introduction 1(16) Scope of the Subject 1(1) Historical Development 1(13) Types of Production 14(3) References 14(3) Metal Cutting Operations 17(54) Introduction 17(1) Turning 17(3) Boring 20(1) Drilling 21(6) Reaming 27(1) Milling 28(5) Planing and Shaping 33(1) Broaching 33(2) Tapping and Threading 35(9) Grinding and Related Abrasive Processes 44(8) Roller Burnishing 52(2) Deburring 54(1) Examples 54(12) Problems 66(5) References 68(3) Machine Tools 71(70) Introduction 71(1) Production Machine Tools 72(5) CNC Machine Tools and Cellular Manufacturing Systems 77(14) Machine Tool Structures 91(11) Slides and Guideways 102(4) Axis Drives 106(5) Spindles 111(15) Coolant Systems 126(1) Tool Changing Systems 126(3) Examples 129(12) References 133(8) Cutting Tools 141(124) Introduction 141(1) Cutting Tool Materials 141(14) Tool Coatings 155(7) Basic Types of Cutting Tools 162(1) Turning Tools 163(10) Boring Tools 173(6) Milling Tools 179(13) Drilling Tools 192(31) Reamers 223(5) Threading Tools 228(8) Grinding Wheels 236(7) Microsizing and Honing Tools 243(2) Burnishing Tools 245(1) Examples 245(13) Problems 258(7) References 258(7) Toolholders and Workholders 265(106) Introduction 265(1) Toolholding Systems 265(5) Toolholder-Spindle Connection 270(43) Cutting Tool Clamping Systems 313(28) Balancing Requirements for Toolholders 341(6) Fixtures 347(6) Examples 353(13) Problems 366(5) References 366(5) Mechanics of Cutting 371(54) Introduction 371(1) Measurement of Cutting Forces and Chip Thickness 371(3) Force Components 374(4) Empirical Force Models 378(2) Specific Cutting Power 380(2) Chip Formation and Primary Plastic Deformation 382(7) Tool--Chip Friction and Secondary Deformation 389(5) Shear Plane and Slip-Line Theories for Continuous Chip Formation 394(4) Shear Plane Models for Oblique Cutting 398(1) Shear Zone Models 399(4) Minimum Work and Uniqueness Assumptions 403(1) Finite Element Models 404(4) Discontinuous Chip Formation 408(3) Built-up Edge Formation 411(2) Examples 413(2) Problems 415(10) References 416(9) Cutting Temperatures 425(34) Introduction 425(1) Measurement of Cutting Temperatures 425(7) Factors Affecting Cutting Temperatures 432(2) Analytical Models for Steady-State Temperatures 434(3) Finite Element and Other Numerical Models 437(4) Temperatures in Interrupted Cutting 441(3) Temperatures in Drilling 444(2) Thermal Expansion 446(2) Examples 448(3) Problems 451(8) References 451(8) Machining Process Analysis 459(44) Introduction 459(1) Turning 460(2) Boring 462(3) Milling 465(5) Drilling 470(8) Force Equations and Baseline Data 478(4) Process Simulation Application Examples 482(2) Finite Element Analysis for Clamping, Fixturing, and Workpiece Distortion Applications 484(5) Finite Element Application Examples 489(4) Examples 493(6) Problems 499(4) References 499(4) Tool Wear and Tool Life 503(48) Introduction 503(1) Types of Tool Wear 504(4) Measurement of Tool Wear 508(4) Tool Wear Mechanisms 512(2) Tool Wear --- Material Considerations 514(7) Tool Life Testing 521(1) Tool Life Equations 522(3) Prediction of Tool Wear Rates 525(3) Tool Fracture and Edge Chipping 528(2) Drill Wear and Breakage 530(4) Thermal Cracking and Tool Fracture in Milling 534(3) Tool Wear Monitoring 537(1) Examples 537(6) Problems 543(8) References 545(6) Surface Finish and Integrity 551(26) Introduction 551(1) Measurement of Surface Finish 552(6) Surface Finish in Turning and Boring 558(4) Surface Finish in Milling 562(3) Surface Finish in Drilling and Reaming 565(1) Surface Finish in Grinding 566(2) Residual Stresses in Machined Surfaces 568(1) White Layer Formation 569(1) Surface Burn in Grinding 570(1) Examples 571(2) Problems 573(4) References 574(3) Machinability of Materials 577(40) Introduction 577(1) Machinability Criteria, Tests, and Indices 578(4) Chip Control 582(6) Burr Formation and Control 588(3) Machinability of Engineering Materials 591(26) References 611(6) Machining Dynamics 617(88) Introduction 617(1) Vibration Analysis Methods 617(1) Vibration of Discrete (Lumped Mass) Systems 618(12) Types of Machine Tool Vibration 630(2) Forced Vibration 632(4) Self-Excited Vibrations (Chatter) 636(17) Chatter Prediction 653(5) Vibration Control 658(4) Active Vibration Control 662(7) Examples 669(22) Problems 691(14) References 697(8) Machining Economics and Optimization 705(62) Introduction 705(2) Role of a Computerized Optimization System 707(1) Economic Considerations 708(2) Optimization of Machining Systems --- Basic Factors 710(1) Optimization of Machining Conditions 711(1) Formulation of the Optimization Problem 712(7) Optimization Techniques 719(22) Examples 741(17) Problems 758(9) References 760(7) Cutting Fluids 767(20) Introduction 767(1) Types of Cutting Fluids 768(3) Coolant Application 771(2) Filtering 773(5) Condition Monitoring and Waste Treatment 778(1) Health and Safety Concerns 779(2) Dry and Near-Dry Machining Methods 781(2) Test Procedure for Cutting Fluid Evaluation 783(4) References 783(4) High Throughput and Agile Machining 787(18) Introduction 787(1) High Throughput Machining 787(2) Agile Machining Systems 789(2) Tooling and Fixturing 791(9) Materials Handling Systems 800(5) References 802(3) Design for Machining 805(28) Introduction 805(1) Machining Costs 805(1) General Design for Machining Rules 806(7) Special Considerations for Specific Types of Equipment and Operations 813(4) CAPP and DFM Programs 817(2) Part Quality Modeling 819(3) Examples 822(11) References 831(2) Index 833