Metal_Machining.pdf

Metal Machining

Theory and Applications

Thomas Childs

University of Leeds, UK

Katsuhiro Maekawa

Ibaraki University, Japan

Toshiyuki Obikawa

Tokyo Institute of Technology, Japan

Yasuo Yamane

Hiroshima University, Japan

A member of the Hodder Headline Group

LONDON

Copublished in North, Central and South America

by John Wiley & Sons Inc.

New York-Toronto

First published in Great Britain in 2000 by

Arnold, a member of the Hodder Headline Group,

338 Euston Road, London NW1 3BH

http://www.arnoldpublishers.com

Copublished in North, Central and South America by

John Wiley & Sons Inc., 605 Third Avenue,

New York, NY 10158–0012

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are issued by the Copyright Licensing Agency: 90 Tottenham Court Road,

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Whilst the advice and information in this book are believed to be true and

accurate at the date of going to press, neither the authors nor the publisher

can accept any legal responsibility or liability for any errors or omissions

that may be made.

British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library

Library of Congress Cataloging-in-Publication Data

A catalog record for this book is available from the Library of Congress

ISBN 0 340 69159 X

ISBN 0 470 39245 2 (Wiley)

1 2 3 4 5 6 7 8 9 10

Commissioning Editor: Matthew Flynn

Production Editor: James Rabson

Production Controller: Iain McWilliams

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Contents

Preface

vii

1 Introduction

1.1 Machine tool technology

1.2 Manufacturing systems

1.3 Materials technology

1.4 Economic optimization of machining

1.5 A forward look

References

2 Chip formation fundamentals

2.1 Historical introduction

2.2 Chip formation mechanics

2.3 Thermal modelling

2.4 Friction, lubrication and wear

2.5 Summary

References

3 Work and tool materials

3.1 Work material characteristics in machining

3.2 Tool materials

References

117

4 Tool damage

118

4.1 Tool damage and its classification

118

4.2 Tool life

130

4.3 Summary

134

References

135

5 Experimental methods

136

5.1 Microscopic examination methods

136

5.2 Forces in machining

139

5.3 Temperatures in machining

147

iv Contents

5.4 Acoustic emission

155

References

157

6 Advances in mechanics

159

6.1 Introduction

159

6.2 Slip-line field modelling

159

6.3 Introducing variable flow stress behaviour

168

6.4 Non-orthogonal (three-dimensional) machining

177

References

197

7 Finite element methods

199

7.1 Finite element background

199

7.2 Historical developments

204

7.3 The Iterative Convergence Method (ICM)

212

7.4 Material flow stress modelling for finite element analyses

220

References

224

8 Applications of finite element analysis

226

8.1 Simulation of BUE formation

226

8.2 Simulation of unsteady chip formation

234

8.3 Machinability analysis of free cutting steels

240

8.4 Cutting edge design

251

8.5 Summary

262

References

262

9 Process selection, improvement and control

265

9.1 Introduction

265

9.2 Process models

267

9.3 Optimization of machining conditions and expert system applications

283

9.4 Monitoring and improvement of cutting states

305

9.5 Model-based systems for simulation and control of machining

processes

317

References

324

Appendices

1 Metals’ plasticity, and its finite element formulation

328

A1.1 Yielding and flow under triaxial stresses: initial concepts

329

A1.2 The special case of perfectly plastic material in plane strain

332

A1.3 Yielding and flow in a triaxial stress state: advanced analysis

340

A1.4 Constitutive equations for numerical modelling

343

A1.5 Finite element formulations

348

References

350

2 Conduction and convection of heat in solids

351

A2.1 The differential equation for heat flow in a solid

351

A2.2 Selected problems, with no convection

353

Contents v

A2.3 Selected problems, with convection

355

A2.4 Numerical (finite element) methods

357

References

362

3 Contact mechanics and friction

363

A3.1 Introduction

363

A3.2 The normal contact of a single asperity on an elastic foundation

365

A3.3 The normal contact of arrays of asperities on an elastic foundation

368

A3.4 Asperities with traction, on an elastic foundation

369

A3.5 Bulk yielding

371

A3.6 Friction coefficients greater than unity

373

References

374

4 Work material: typical mechanical and thermal behaviours

375

A4.1 Work material: room temperature, low strain rate, strain hardening

behaviours

375

A4.2 Work material: thermal properties

376

A4.3 Work material: strain hardening behaviours at high strain rates and

temperatures

379

References

381

5 Approximate tool yield and fracture analysis

383

A5.1 Tool yielding

383

A5.2 Tool fracture

385

References

386

6 Tool material properties

387

A6.1 High speed steels

387

A6.2 Cemented carbides and cermets

388

A6.3 Ceramics and superhard materials

393

References

395

7 Fuzzy logic

396

A7.1 Fuzzy sets

396

A7.2 Fuzzy operations

398

References

400

Index

401

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