Manufacturing Processes 1

by Klocke, Fritz; Kuchle, Aaron

• ISBN13: 9783642119781
• ISBN10: 3642119786
• Format: Hardcover
• Copyright: 2011-06-09
• Publisher: Springer Verlag

Summary

Volume 1 of the five-volume "Manufacturing Processes" addresses the basics of machining with geometrically defined cutting edges, proceeding from a common working principle. Loads and the stress-appropriate design of machining tools as well as the sensible application of cutting materials are introduced, providing a prerequisite for more detailed considerations of particular methodological alternatives.An extensive chapter concerning the machinability of the most important work-piece materials such as steels and cast iron, light metal alloys and high-temperature materials will provide a broad perspective on the mutual interdependence of materials, cutting materials and procedural parameters. New chapters on the machinability of magnesium and non-metallic materials as well as on the use of numerical simulation methods in machining technology complete the volume.

Table of Contents

Introduction	p. 1
Metrology and Work piece Quality	p. 3
Manufacturing Disturbances and Manufacturing History	p. 3
Measuring and Testing	p. 8
Measurement Errors	p. 9
Macro-and Micro geometry of Components	p. 10
Length Testing Devices	p. 13
Material Measures	p. 13
Gauges	p. 13
Indicating Measuring Instruments	p. 14
Surface Inspection	p. 21
Surface Parameters	p. 22
Subjective Surface Inspection	p. 26
Surface Measurement	p. 27
Inspection of the Work piece Rim	p. 30
Surface Layers	p. 31
Inspection of the Surface Rim Zone	p. 33
Fundamentals of Cutting	p. 39
The Cutting Part - Concepts and Terms	p. 39
Reference Systems	p. 42
Basic Process Variants	p. 45
Chip Formation	p. 47
The Cutting Process	p. 47
Different Types of Chip Formation	p. 49
Kinematic Surface Roughness	p. 54
Mechanical and Thermal Strain on the Cutting Section	p. 55
Influence of the Geometry of the Cutting Section	p. 68
Wear	p. 71
Wear Mechanisms	p. 71
Causes of Wear	p. 74
Forms and Dimensions of Wear	p. 85
Cutting Theory	p. 87
Shear Plane Theory	p. 87
Application of Plasticity Theory to Cutting	p. 92
Cutting Tool Materials and Tools	p. 95
Overview of Cutting Tool Materials	p. 95
Classification of Hard Cutting Tool Materials	p. 97
Tool Steels	p. 99
Cold Work Steels	p. 100
High Speed Steels	p. 101
Cemented Carbides	p. 110
Historical Development	p. 111
Cemented Carbide Production	p. 112
Components of Cemented Carbides and Their Properties	p. 114
Microstructure	p. 116
Classification of Cemented Carbides	p. 117
Uncoated Cemented Carbides and Cermets	p. 123
Function Gradient Cemented Carbides	p. 123
Coated Cemented Carbides and Cermets	p. 126
Coatings	p. 127
Coating Methods	p. 128
Specific Properties of Hard Material Coatings	p. 149
Substrate Pretreatment	p. 161
Ceramic Cutting Tool Materials	p. 161
Cutting Ceramics	p. 162
Superhard Non-metallic Cutting Tool Materials	p. 173
Tool Designs	p. 184
Solid Tools	p. 185
Tools with Inserts	p. 187
Tool Preparation	p. 193
Finite Element Method (FEM)	p. 197
Basic Concepts of FEM	p. 197
Lagrangian and Eulerian Considerations of the Continuum	p. 199
Explicit and Implicit Methods of Solution	p. 199
Combined Thermal and Mechanical FEA	p. 200
Nonlinearities	p. 200
Material Laws	p. 201
Software	p. 204
Hardware	p. 205
Phases of a Finite Element Analysis (FEA)	p. 205
The Use of FEM in Cutting Technology	p. 206
Continuous Chip Simulation	p. 207
Segmented Chip Simulation	p. 209
Simulation of the Cutting Process	p. 212
Cutting Fluids	p. 219
The Functions of Cutting Fluids	p. 219
Types of Cutting Fluids	p. 219
Non Water-Miscible Cutting Fluids	p. 220
Water-Based Cutting Fluids	p. 221
Guidelines on the Use of Coolant Emulsions	p. 222
Effects of the Cutting Fluid on the Machining Process	p. 223
Selection of Cutting Fluids	p. 226
Reducing or Avoiding the Use of Cutting Fluids	p. 227
Reducing Cutting Fluids	p. 228
Minimum Quantity Cooling Lubrication (MQCL)	p. 229
Avoiding Cutting Fluids	p. 233
Too Life Behaviour	p. 237
Determining Tool Life Parameters	p. 239
Machinability	p. 239
Tool Life	p. 240
Resultant Force	p. 243
Surface Quality	p. 245
Chip Form	p. 248
Cutting Speed'	p. 248
The Machinability of Steel Materials	p. 249
Metallographic Constituents	p. 250
Carbon Content	p. 252
Alloying Elements	p. 254
Types of Heat Treatment	p. 256
Machinability of Various Steel Materials	p. 263
Machining Steels	p. 263
Case-Hardened Steels	p. 266
Heat-Treatable Steels	p. 267
Nitrided Steels	p. 268
Tool Steels	p. 269
Hardened Steels	p. 271
Non-rusting Steels	p. 274
Machinability of Cast Iron	p. 280
White Cast Iron	p. 280
GreyCastlron	p. 283
Machinability of Non-ferrous Metals	p. 290
Aluminium Alloys	p. 290
Magnesium Alloys	p. 293
Titanium Alloys	p. 296
Copper Alloys	p. 311
NickelAlloys	p. 314
Machinability of Non-metals	p. 327
Graphite	p. 327
Fibre-Reinforced Plastics	p. 331
Process Design and Process Monitoring	p. 339
Finding Economical Cutting Parameters	p. 339
Cutting Parameter Limits	p. 339
Optimizing the Cutting Parameters	p. 342
Calculating the Machine Hour-Rate	p. 350
Planning Methods and Tools	p. 351
Process Monitoring	p. 352
Sensors for Process Monitoring	p. 354
Signal Processing and Monitoring Strategies	p. 371
Processes with Rotational Primary Movement	p. 383
Turning	p. 383
Face Turning	p. 385
Cylindrical Turning	p. 386
Helical Turning	p. 387
Profile Turning	p. 388
Form Turning	p. 389
Further Process Variants	p. 390
Milling	p. 390
Process Variants, Specific Characteristics and Tools	p. 395
Drilling	p. 416
Profile Counterboring	p. 416
Rotary Drilling	p. 418
Sawing	p. 439
Bandsawing	p. 439
Hacksawmg	p. 442
Circular Sawing	p. 442
Processes with Translatory Primary Movement	p. 445
Broaching	p. 445
Face and Circular Broaching	p. 446
Profile Broaching	p. 449
Form Broaching	p. 451
Shaving	p. 454
Planing and Shaping	p. 457
Face Shaping and Face Planing	p. 458
Gear Shaping	p. 459
Gear Planing	p. 466
References	p. 469
Subject Index	p. 497
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