Tribology of Metal Cutting

by Astakhov

• ISBN13: 9780444528810
• ISBN10: 0444528814
• Format: Hardcover
• Copyright: 2006-12-18
• Publisher: Elsevier Science

Summary

The term tribology is from the Greek tribos, meaning friction, and logos, meaning law. Tribology is therefore defined as 'the science and technology of interactive surfaces moving relative to each other'. The science of Tribology concentrates on contact physics and mechanics of moving interfaces that generally involve energy dissipation. To comprehend the scope of metal cutting tribology, it should be clearly realized that the ultimate objective of metal cutting tribology is the reduction of the energy spent in metal cutting. Increased tool life, improved integrity of the machined surface, higher process efficiency and stability are the results of achieving this goal. This book attempts to provide specialists in the field of metal cutting with information on how to make metal cutting tribology useful at various levels (starting with tool design, developing and/or selecting proper tool materials including coating, development and/or selecting proper cutting fluids and ending with cutting process optimization on the shop floor).

Table of Contents

Preface	p. ix
Generalized Model of Chip Formation	p. 1
Introduction	p. 1
Inadequacy of the Single-Shear Plane Model	p. 2
What is the Model of Chip Formation?	p. 21
System Concept in Metal Cutting	p. 23
Generalized Model of Chip Formation	p. 23
Influence of Cutting Speed	p. 43
Formation of Saw-Toothed Chip	p. 48
Frequency of Chip Formation	p. 53
Formation of the Segmental Saw-Toothed Chip	p. 55
Applicability and Significance of Chip Formation Models	p. 60
References	p. 62
Energy Partition in the Cutting System	p. 69
Introduction	p. 69
Energy Flows in the Cutting System	p. 70
Physical Efficiency of the Cutting System	p. 73
Determination of the Work of Plastic Deformation in Metal Cutting	p. 76
Practical Analysis of the Physical Efficiency of the Cutting System	p. 91
Energy Balance of the Cutting System	p. 94
Methods of Improving Physical Efficiency of the Cutting System	p. 98
References	p. 120
Tribology of the Tool-Chip and Tool-Workpiece Interfaces	p. 124
Introduction	p. 124
Tool-Chip Interface	p. 125
Tool-Workpiece Interface	p. 177
Temperature at the Interfaces	p. 189
References	p. 211
Cutting Tool Wear, Tool Life and Cutting Tool Physical Resource	p. 220
Introduction	p. 220
Known Approaches	p. 221
Proper Assessment of Tool Wear	p. 224
Optimal Cutting Temperature - The First Metal Cutting Law	p. 227
Influence of Cutting Feed and Depth of Cut	p. 239
Influence of Tool Geometry	p. 245
Influence of Workpiece Diameter	p. 248
Plastic Lowering of the Cutting Edge	p. 254
Resource of the Cutting Wedge	p. 269
References	p. 274
Design of Experiments in Metal Cutting Tests	p. 276
Introduction	p. 276
DOE in Machining: Terminology and Requirements	p. 277
Screening Test	p. 281
2k Factorial Experiment, Complete Block	p. 294
Group Method of Data Handling	p. 307
References	p. 323
Improvements of Tribological Conditions	p. 326
Cutting Fluids (Coolants)	p. 327
Coatings	p. 372
Improving Tribological Conditions by Modification of Properties of the Work Material	p. 379
References	p. 386
Basics, Definitions and Cutting Tool Geometry	p. 391
Basic Terms and Definitions	p. 391
Reference Planes	p. 394
Angles: Definitions	p. 396
Determination of Uncut Chip Thickness for a General Case	p. 410
References	p. 413
Experimental Determination of the Chip Compression Ratio (CCR)	p. 414
General Experimental Techniques	p. 414
Design of Experiment	p. 416
Index	p. 419
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