Metal Cutting Theory and Practice: 3rd Edition (Hardback) book cover

Metal Cutting Theory and Practice

3rd Edition

By David A. Stephenson, John S. Agapiou

CRC Press

947 pages | 732 B/W Illus.

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pub: 2016-03-24
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Description

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.

Reviews

"This book covers the most important aspects about machining with grinding wheels and is an ideal handbook not only for beginners but also professionals in this area."

—Professor from Saint Louis University, Missouri, USA

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 Authors

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.

Subject Categories

BISAC Subject Codes/Headings:
SCI041000
SCIENCE / Mechanics / General
TEC009060
TECHNOLOGY & ENGINEERING / Industrial Engineering
TEC020000
TECHNOLOGY & ENGINEERING / Manufacturing
TEC021000
TECHNOLOGY & ENGINEERING / Material Science
TEC023000
TECHNOLOGY & ENGINEERING / Metallurgy