Description
Taylor and Francis Metal Cutting Theory And Practice 3Rd Edition by STEPHENSON D A
A Complete Reference Covering the Latest Technology in Metal Cutting Tools, Processes, and Equipment
Metal Cutting Theory and Practice, Third Edition shapes the future of material removal in new and lasting ways. Centered on metallic work materials and traditional chip-forming cutting methods, the book provides a physical understanding of conventional and high-speed machining processes applied to metallic work pieces, and serves as a basis for effective process design and troubleshooting. This latest edition of a well-known reference highlights recent developments, covers the latest research results, and reflects current areas of emphasis in industrial practice. Based on the authors’ extensive automotive production experience, it covers several structural changes, and includes an extensive review of computer aided engineering (CAE) methods for process analysis and design. Providing updated material throughout, it offers insight and understanding to engineers looking to design, operate, troubleshoot, and improve high quality, cost effective metal cutting operations.
The book contains extensive up-to-date references to both scientific and trade literature, and provides a description of error mapping and compensation strategies for CNC machines based on recently issued international standards, and includes chapters on cutting fluids and gear machining. The authors also offer updated information on tooling grades and practices for machining compacted graphite iron, nickel alloys, and other hard-to-machine materials, as well as a full description of minimum quantity lubrication systems, tooling, and processing practices. In addition, updated topics include machine tool types and structures, cutting tool materials and coatings, cutting mechanics and temperatures, process simulation and analysis, and tool wear from both chemical and mechanical viewpoints.
Comprised of 17 chapters, this detailed study:
• Describes the common machining operations used to produce specific shapes or surface characteristics
• Contains conventional and advanced cutting tool technologies
• Explains the properties and characteristics of tools which influence tool design or selection
• Clarifies the physical mechanisms which lead to tool failure and identifies general strategies for reducing failure rates and increasing tool life
• Includes common machinability criteria, tests, and indices
• Breaks down the economics of machining operations
• Offers an overview of the engineering aspects of MQL machining
• Summarizes gear machining and finishing methods for common gear types, and more
Metal Cutting Theory and Practice, Third Edition emphasizes the physical understanding and analysis for robust process design, troubleshooting, and improvement, and aids manufacturing engineering professionals, and engineering students in manufacturing engineering and machining processes programs.
Key Features
• Serves as a complete reference that covers systems, machines, processes, and theory
• Emphasizes physical insight and a model-based approach to problem solving
• Provides extensive coverage of tool grades and coatings for all engineering materials
• Includes a full-scale treatment of minimum quality lubrication machining
• Offers worked examples to illustrate applications and extensive troubleshooting charts for specific processe
Table of Contents
Introduction
Scope of the Subject
Historical Development
References
Metal Cutting Operations
Introduction
Turning
Boring
Drilling
Reaming
Milling
Planing and Shaping
Broaching
Tapping and Threading
Grinding and Related Abrasive Processes
Roller Burnishing
Deburring
Examples
Problems
References
Machine Tools
Introduction
Production Machine Tools
CNC Machine Tools and CNC-Based Manufacturing Systems
Machine Tool Structures
Slides and Guideways
Axis Drives
Spindles
Coolant Systems
Tool Changing Systems
Pallets
Energy Use in CNC Machining Centers
Examples
References
Cutting Tools
Introduction
Cutting Tool Materials
Tool Coatings
Basic Types of Cutting Tools
Turning Tools
Boring Tools
Milling Tools
Drilling Tools
Reamers
Threading Tools
Grinding Wheels
Microsizing and Honing Tools
Burnishing Tools
Examples
Problems
References
Toolholders and Workholders
Introduction
Toolholding Systems
Toolholder/Spindle Connections
Cutting Tool Clamping Systems
Balancing Requirements for Toolholders
Fixtures
Examples
Problems
References
Mechanics of Cutting
Introduction
Measurement of Cutting Forces and Chip Thickness
Force Components
Empirical Force Models
Specific Cutting Power
Chip Formation and Primary Plastic Deformation
Tool-Chip Friction and Secondary Deformation
Shear Plane and Slip Line Theories for Continuous Chip Formation
Shear Plane Models for Oblique Cutting
Shear Zone Models
Minimum Work and Uniqueness Assumptions
Finite Element Models
Discontinuous Chip Formation
Built-up Edge Formation
Examples
Problems
References
Cutting Temperatures
Introduction
Measurement of Cutting Temperatures
Factors Affecting Cutting Temperatures
Analytical Models for Steady-State Temperatures
Finite Element and Other Numerical Models
Temperatures in Interrupted Cutting
Temperatures in Drilling
Thermal Expansion
Examples
Problems
References
Machining Process Analysis
Introduction
Turning
Boring
Milling
Drilling
Force Equations and Baseline Data
Process Simulation Application Examples
Finite Element Analysis for Clamping, Fixturing, and Workpiece Distortion
Applications
Finite Element Application Examples
Examples
Problems
References
Tool Wear and Tool Life
Introduction
Types of Tool Wear
Measurement of Tool Wear
Tool Wear Mechanisms
Tool Wear--Material Considerations
Tool Life Testing
Tool Life Equations
Prediction of Tool Wear Rates
Tool Fracture and Edge Chipping
Drill Wear and Breakage
Thermal Cracking and Tool Fracture in Milling
Tool Wear Monitoring
Examples
Problems
References
Surface Finish, Integrity, and Flatness
Introduction
Measurement of Surface Finish
Surface Finish in Turning and Boring
Surface Finish in Milling
Surface Finish in Drilling and Reaming
Surface Finish in Grinding
Residual Stresses in Machined Surfaces
White Layer Formation
Surface Burning in Grinding
Measurement of Surface Flatness
Surface Flatness Compensation in Face Milling
Examples
Problems
References
Machinability of Materials
Introduction
Machinability Criteria, Tests, and Indices
Chip Control
Burr Formation and Control
Machinability of Engineering Materials
References
Machining Dynamics
Introduction
Vibration Analysis Methods
Vibration of Discrete (Lumped Mass) Systems
Types of Machine Tool Vibration
Forced Vibration
Self-Excited Vibrations (Chatter)
Chatter Prediction
Vibration Control
Active Vibration Control
Examples
Problems
References
Machining Economics and Optimization
Introduction
Role of a Computerized Optimization System
Economic Considerations
Optimization of Manufacturing Systems--Basic Factors
Optimization of Machining Conditions
Formulation of the Optimization Problem
Optimization Techniques
Examples
Problems
References
Cutting Fluids
Introduction
Types of Cutting Fluids
Coolant Application
Filtering
Condition Monitoring and Waste Treatment
Health and Safety Concerns
Dry and Near-Dry Machining Methods
Test Procedure for Cutting Fluid Evaluation
References
Minimum Quantity Lubrication
Introduction
MQL System Types
MQL Oils
Machine Tools for MQL
MQL Cutting Tools
Thermal Management and Dimensional Control
Air and Chip Handling
MQL Research Areas
References
Accuracy and Error Compensation of CNC Machining Systems
Introduction
Machine Tool Errors
Machine Tool Accuracy Characterization
Machine Tool Performance Evaluation
Method for Compensating the Dimensional Accuracy of CNC Machining System
Examples
References
About the Author
David A. Stephenson is a technical specialist at Ford Powertrain Advanced Manufacturing Engineering in Livonia, Michigan. Earlier, Stephenson worked for several years at General Motors Research and General Motors Powertrain; he has also worked at Third Wave Systems, Inc., D3 Vibrations, Inc., the University of Michigan, and Fusion Coolant Systems. He is a member of the American Society of Mechanical Engineers (ASME) and a Fellow of the Society of Manufacturing Engineers (SME). He has served as a journal technical editor for both societies, and served on the ASME Manufacturing Science and Engineering Division Executive Commitee from 2002 to 2007.
John S. Agapiou is a technical fellow at the Manufacturing Systems Research Lab at General Motors R&D Center, Warren, Michigan. He is also part time professor in the Department of Mechanical Engineering at Wayne State University. His research focus involves developing and implementing world-class manufacturing, quality, and process validation strategies in the production and development of the automotive Powertrain. He received his bachelor’s and master’s degrees in mechanical engineering at the University of Louisville in 1980 and 1981, respectively, and his PhD from the University of Wisconsin in 1985.