Metal Cutting Theory and Practice

INTRODUCTION Scope of the Subject Historical Development Types of Production 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 Cellular Manufacturing Systems Machine Tool Structures Slides and Guideways Axis Drives Spindles Coolant Systems Tool Changing Systems 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 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 AND INTEGRITY 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 Burn in Grinding 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 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 Numerical 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 HIGH THROUGHPUT AND AGILE MACHINING Introduction High Throughput Machining Agile Machining Systems Tooling and Fixturing Materials Handling Systems References DESIGN FOR MACHINING Introduction Machining Costs General Design for Machining Rules Special Considerations for Specific Types of Equipment and Operations CAPP and DFM Programs Examples References INDEX