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Metal Cutting Theory and Practice Manufacturing title: Engineering and Materials Processing ; 49 author: Stephenson, David A.; Agapiou, John S. publisher: CRC Press isbn10 | asin: 0824795792 print isbn13: 9780824795795 ebook isbn13: 9780585139210 language: English subject Metal-cutting. publication ...

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Metal Cutting Theory and Practice Manufacturing Engineering and Materials Processing ; 49 Stephenson, David A.; Agapiou, John S. CRC Press 0824795792 9780824795795 9780585139210 English Metal-cutting. 1997 TJ1185.S815 1997eb 671.5/3 Metal-cutting.

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Metal Cutting Theory and Practice

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MANUFACTURING ENGINEERING AND MATERIALS PROCESSING A Series of Reference Books and Textbooks FOUNDING EDITOR Geoffrey Boothroyd University of Rhode Island Kingston, Rhode Island 1. Computers in Manufacturing, U. Rembold, M. Seth, and J. S. Weinstein 2. Cold Rolling of Steel, William L. Roberts 3. Strengthening of Ceramics: Treatments, Tests, and Design Applications, Harry P. Kirchner 4. Metal Forming: The Application of Limit Analysis, Betzalel Avitzur 5. Improving Productivity by Classification, Coding, and Data Base Standardization: The Key to Maximizing CAD/CAM and Group Technology, William F. Hyde 6. Automatic Assembly, Geoffrey Boothroyd, Corrado Poli, and Laurence E. Murch 7. Manufacturing Engineering Processes, Leo Alting 8. Modern Ceramic Engineering: Properties, Processing, and Use in Design, David W. Richerson 9. Interface Technology for Computer-Controlled Manufacturing Processes, Ulrich Rembold, Karl Armbruster, and Wolfgang Ülzmann 10. Hot Rolling of Steel, William L. Roberts 11. Adhesives in Manufacturing, edited by Gerald L. Schneberger 12. Understanding the Manufacturing Process: Key to Successful CAD/CAM Implementation, Joseph Harrington, Jr. 13. Industrial Materials Science and Engineering, edited by Lawrence E. Murr 14. Lubricants and Lubrication in Metalworking Operations, Elliot S. Nachtman and Serope Kalpakjian 15. Manufacturing Engineering: An Introduction to the Basic Functions, John P. Tanner 16. Computer-Integrated Manufacturing Technology and Systems, Ulrich Rembold, Christian Blume, and Ruediger Dillman 17. Connections in Electronic Assemblies, Anthony J. Bilotta 18. Automation for Press Feed Operations: Applications and Economics, Edward Walker 19. Nontraditional Manufacturing Processes, Gary F. Benedict 20. Programmable Controllers for Factory Automation, David G. Johnson 21. Printed Circuit Assembly Manufacturing, Fred W. Kear

22. Manufacturing High Technology Handbook, edited by Donatas Tijunelis and Keith E. McKee

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23. Factory Information Systems: Design and Implementation for CIM Management and Control, John Gaylord 24. Flat Processing of Steel, William L. Roberts 25. Soldering for Electronic Assemblies, Leo P. Lambert 26. Flexible Manufacturing Systems in Practice: Applications, Design, and Simulation, Joseph Talavage and Roger G. Hannam 27. Flexible Manufacturing Systems: Benefits for the Low Inventory Factory, John E. Lenz 28. Fundamentals of Machining and Machine Tools: Second Edition, Geoffrey Boothroyd and Winston A. Knight 29. Computer-Automated Process Planning for World-Class Manufacturing, James Nolen 30. Steel-Rolling Technology: Theory and Practice, Vladimir B. Ginzburg 31. Computer Integrated Electronics Manufacturing and Testing, Jack Arabian 32. In-Process Measurement and Control, Stephan D. Murphy 33. Assembly Line Design: Methodology and Applications, We-Min Chow 34. Robot Technology and Applications, edited by Ulrich Rembold 35. Mechanical Deburring and Surface Finishing Technology, Alfred F. Scheider 36. Manufacturing Engineering: An Introduction to the Basic Functions, Second Edition, Revised and Expanded, John P. Tanner 37. Assembly Automation and Product Design, Geoffrey Boothroyd 38. Hybrid Assemblies and Multichip Modules, Fred W. Kear 39. High-Quality Steel Rolling: Theory and Practice, Vladimir B. Ginzburg 40. Manufacturing Engineering Processes: Second Edition, Revised and Expanded, Leo Alting 41. Metalworking Fluids, edited by Jerry P. Byers 42. Coordinate Measuring Machines and Systems, edited by John A. Bosch 43. Arc Welding Automation, Howard B. Cary 44. Facilities Planning and Materials Handling: Methods and Requirements, Vijay S. Sheth 45. Continuous Flow Manufacturing: Quality in Design and Processes, Pierre C. Guerindon 46. Laser Materials Processing, edited by Leonard Migliore 47. Re-Engineering the Manufacturing System: Applying the Theory of Constraints, Robert E. Stein 48. Handbook of Manufacturing Engineering, edited by Jack M. Walker

49. Metal Cutting Theory and Practice, David A. Stephenson and John S. Agapiou Additional Volumes in Preparation

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Metal Cutting Theory and Practice David A. Stephenson John S. Agapiou

MARCEL DEKKER, INC. NEW YORK BASEL

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Library of Congress Cataloging-in-Publication Data Stephenson, David A. Metal cutting theory and practice / David A. Stephenson, John S. Agapiou. p. cm. Includes bibliographical references and index. ISBN 0-8247-9579-2 (alk. paper) 1. Metal-cutting. I. Agapiou, John S. II. Title. TJ1185.S815 1996 671.5'3DC20 96-41102 CIP The publisher offers discounts on this book when ordered in bulk quantities. For more information, write to Special Sales/Professional Marketing at the address below. This book is printed on acid-free paper. Copyright © 1997 by MARCEL DEKKER, INC. All Rights Reserved. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any information storage and retrieval system, without permission in writing from the publisher. MARCEL DEKKER, INC. 270 Madison Avenue. New York, New York 10016 Current printing (last digit): 10 9 8 7 6 5 4 3 2 PRINTED IN THE UNITED STATES OF AMERICA

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Preface Metal cutting is a subject as old as the Industrial Revolution, but one that has evolved continuously as technology has advanced. The first metal-cutting machine tools, built some 450 years ago, were powered by water and employed iron and carbon steel tools. Over time, these gave way to machines powered by steam and leather belts employing high-speed steel tools, to electrically powered machines using sintered carbide tools, and most recently to computer-controlled machines using ceramic and diamond tools. The pace of change seems to have increased over the last twenty years, with progressively rapid advances in materials science and computer technology. For example, since the beginning of our own careers, typical production rates have doubled in many operations, and numerous new tool materials, work materials, and machine architectures have been introduced-and we are still many years from retirement. Our purpose in writing this book is twofold. First, many of the books from which we learned much of our trade were written in the 1970's or earlier, and despite recent updated editions, they are showing inevitable signs of age. We hoped to write a reference book that would provide a fuller treatment of recent developments than is currently available. Second, the literature in this field is somewhat dichotomous, consisting on the one hand of scientific books and articles read largely by academics and researchers, and on the other hand of trade journals, handbooks, and sales brochures read by practicing engineers. We also hoped to write a book which would appeal to both audiences by covering both research results and the current industrial practice. To make the project manageable we had to limit the technical topics to be covered. We have chosen to consider only metallic work materials, to concentrate on the traditional chip-forming cutting processes with limited material on abrasive processes, and to largely ignore subjects such as machine tool control which could fill entire books in their own right. Even with these limitations, we recognize that we have taken on an ambitious subject. Readers, of course, will have to decide how well we have covered it.

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We have been fortunate over the years to have worked with, and learned from, many fine engineers in academia and in the automotive, machine tool, and cutting tool industries. We received valuable feedback on drafts of portions of this book from Robin Stevenson, Pulak Bandyopadhyay, Yhu-Tin Lin, David W. Yen, I. S. Jawahir, Jochen S. Zenker, and Ellen D. Kock. We are grateful to these colleagues for correcting many errors and inconsistencies in the manuscript, and are responsible for all those which still remain. We also thank Simon Yates, Dawn Wechsler, Walter Brownfield, and Vivian Jao of Marcel Dekker, Inc., for their courteous and helpful editing. Finally and most importantly, we thank our wives, Maria Clelia Milletti and Christina Agapiou, and our children, Stylianos Ioannis Agapiou, Alexandra Maria Agapiou, Francesca Laura Stephenson, and Luke Andrew Stephenson, for their patience during the many times when our preoccupation with this project inconvenienced them. DAVID A. STEPHENSON JOHN S. AGAPIOU

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Contents Preface 1. Introduction

iii 1

1.1 Scope of the Subject

1

1.2 Historical Development

2

1.3 Types of Production

9

References 2. Metal Cutting Operations and Machine Tools 2.1 Introduction

10 12 12

2.2 Basic Machining Operations and Conventional Machine 13 Tools 2.3 Production Machine Tools

64

2.4 67 Machining Centers and Cellular Manufacturing Systems 2.5 Machine Tool Structures

76

2.6 Slides and Guideways

86

2.7 Axis Drives

95

2.8

103

Spindles 2.9 Coolant Systems

122

2.10 Tool Changing Systems

123

References

126

3. Cutting Tools

137

3.1 Introduction

137

3.2 Cutting Tool Materials

137

3.3 Tool Coatings

155

3.4 Basic Types of Cutting Tools

164

3.5 Turning Tools

167

3.6 Boring Tools

179

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3.7 Milling Tools

189

3.8 Drilling Tools

205

3.9 Reamers

245

3.10 Threading Tools

251

3.11 Grinding Wheels

264

3.12 Microsizing and Honing Tools

273

3.13 Burnishing Tools

277

References

279

4. Toolholders and Workholders

286

4.1 Introduction

286

4.2 Toolholding Systems

287

4.3 Toolholder/Spindle Connections

304

4.4 Cutting Tool Clamping Systems

357

4.5 Balancing Requirements for Toolholders

390

4.6 Fixtures

395

References

403

5. Chip Formation

408

5.1 Introduction

408

5.2 Types of Chips

408

5.3 Primary Plastic Deformation in Continuous Chip Formation

412

5.4 Tool-Chip Friction and Secondary Deformation

420

5.5 Chip Control

427

5.6 Burr Formation and Control

434

References

439

6. Mechanics of Cutting

447

6.1 Introduction

447

6.2 Measurement of Cutting Forces and Chip Thickness

447

6.3 Force Components

450

6.4 Empirical Force Models

455

6.5 Specific Cutting Energy

459

6.6 Shear Plane and Slip Line Theories for Continuous Chip Formation

461

6.7 Shear Plane Models for Oblique Cutting

466

6.8 Shear Zone Models

468

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6.9 Minimum Work and Uniqueness Assumptions

471

6.10 Finite Element Models

472

6.11 Discontinuous Chip Formation

477

6.12 Built-Up Edge Formation

480

References

482

7. Cutting Temperatures

491

7.1 Introduction

491

7.2 Measurement of Cutting Temperatures

492

7.3 Factors Affecting Cutting Temperatures

501

7.4 Analytical Models for Steady-State Temperatures

502

7.5 Numerical Models

507

7.6 Temperatures in Interrupted Cutting

512

7.7 Temperatures in Drilling

513

7.8 Thermal Expansion

517

References

519

8. Cutting Process Simulation

528

8.1 Definition and Purpose

528

8.2 Turning

529

8.3 Boring

533

8.4 Skiving

535

8.5 Milling

537

8.6 Drilling

548

8.7 Force Equations and Baseline Data

561

8.8 Calculation of Deflections

567

References

571

9. Tool Life

577

9.1 Introduction

577

9.2 Types of Tool Wear

578

9.3 Measurement of Tool Wear

583

9.4 Tool Wear Mechanisms

585

9.5 Tool Wear--Material Considerations

592

9.6 Tool Life Testing

599

9.7 Tool Life Equations

601

9.8 Prediction of Tool Wear Rates

608

9.9 Tool Fracture and Edge Chipping

611

Page viii

9.10 Drill Wear and Breakage

613

9.11 Thermal Cracking and Tool Fracture in Milling

619

References

622

10. Surface Finish

629

10.1 Introduction

629

10.2 Measurement of Surface Finish

630

10.3 Surface Finish in Turning and Boring

638

10.4 Surface Finish in Milling

643

10.5 Surface Finish in Drilling and Reaming

648

10.6 Surface Finish in Grinding

649

10.7 Surface Integrity

651

References

656

11. Machinability of Materials

659

11.1 Introduction

659

11.2 Machinability Criteria, Tests, and Indices

661

11.3 Computerized Machinability Database Systems

666

11.4 Machinability of Engineering Materials

670

11.5 Cutting Fluids

693

References

700

12. Machining Dynamics

708

12.1 Introduction

708

12.2 Vibration Analysis Methods

709

12.3 Vibration of Discrete (Lumped Mass) Systems

711

12.4 Types of Machine Tool Vibration

728

12.5 Forced Vibration

729

12.6 Self-Excited Vibrations (Chatter)

731

12.7 Chatter Prediction

750

12.8 Vibration Control

772

12.9 Active Vibration Control

777

References

787

13. Machining Economics and Optimization

796

13.1 Introduction

796

13.2 Role of a Computerized Optimization System

798

Page ix

13.3 Economic Considerations

801

13.4 803 Optimization of Manufacturing Systems--Basic Factors 13.5 Optimization of Machining Conditions

805

13.6 Formulation of the Optimization Problem

806

13.7 Optimization Techniques

816

13.8 Numerical Examples

849

References

873

Index

883

Page 1

1 Introduction 1.1 Scope of the Subject Metal cutting processes are industrial processes in which metal parts are shaped by removal of unwanted material. In this book we will primarily consider traditional chip-forming processes such as turning, boring, drilling, and milling. In these operations metal is removed as a plastically deformed chip of appreciable dimensions, and a fairly unified physical analysis can be carried out using basic orthogonal and oblique cutting models (Fig. 1.1). Related metal removal processes include abrasive processes, such as grinding and honing, and nontraditional machining processes, such as electrodischarge, ultrasonic, electrochemical, and laser machining. In the abrasive processes metal is removed in the form of small chips produced by a plowing, rather than cutting, mechanism; in the nontraditional processes metal is removed on an much smaller scale by thermal, electrical, or chemical means. In all cases the physical mechanisms of removal differ considerably from those of chip formation, so that different physical analyses are required. Machine tools for grinding and related abrasive processes are similar to those for conventional cutting processes and are described in Chapter 2. Physical analyses of abrasive and nontraditional machining processes are not considered in this book but are available in the literature [16]. Metal cutting processes can also be applied to nonmetalic work materials such as polymers, wood, and ceramics. When these applications are considered, the subject is more commonly called machining. Because of differences in thermomechanical properties, the analyses of metal cutting discussed in this book provide only limited insight into the machining of nonmetals. More relevant information can be found in the literature on the machining of specific classes of materials [7,8].

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Fig.1.1 (a) Orthogonal cutting of a flat workpiece by a wedge-shaped tool. (b) Oblique cutting of a flat workpiece by a wedge-shaped tool.

1.2 Historical Development Metal cutting is a subject in which the industrial practice has always led the theory. The study of metal cutting processes necessarily postdates the development of modern machine tools. Moreover, advances in the field have generally resulted form changes in practice, particularly the introduction of new tool materials. The early development of machine tools has been described by Smiles [9], Roe [10], Rolt [11], and Woodbury [1215]. Woodworking tools with the same kinematic motions as several modern machine tools, such as the pole lathe and

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the bow drill, were developed in ancient times. The first machines for shaping metal accurately were gear and spindle cutting machines used by European clockmakers in the early middle ages. The design of these machines, and the economic constraints on their operation, differ greatly from those of modern machine tools. Leonardo Da Vinci drew designs for a number of machine tools, including various lens grinding machines and a horizontal pipe boring mill with a self-centering chuck. Although these machines are closer in design to modern machine tools, they seem to have served ...