Verfügbarkeit: Metal cutting

Metal cutting: theories and models

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Bibliographische Detailangaben
Weitere Verfasser:	Ståhl, Jan-Eric (HerausgeberIn)
Format:	Buch
Sprache:	English
Veröffentlicht:	Lund Lund Univ. 2012
Ausgabe:	1. ed.
Schlagworte:	Metall Spanende Bearbeitung
Online-Zugang:	Inhaltsverzeichnis
Beschreibung:	III, 580 S. Ill., graph. Darst.
ISBN:	9789163713361

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MARC


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Datensatz im Suchindex

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adam_text	Table of contents PREFACE TO THE FIRST EDITION ....................................................................................... I CO-AUTHORS AND ACKNOWLEDGEMENTS ...................................................................... I PREFACE - SECO TOOLS ...................................................................................................... II BASIC CONTENTS AND AVAILABILITY OF THE MATERIAL .......................................... II PROLOG ................................................................................................................................. ill TABLE OF CONTENTS .......................................................................................................... V WORKPIECE MATERIALS INVOLVED IN THE EXAMPLES GIVEN ..............................XII ABBREVIATIONS ................................................................................................................XII NOMENCLATURE AND SELECTED SYMBOLS EMPLOYED .........................................XIII 1 INTRODUCTION TO METAL CUTTING PROCESS ......................................................19 1.1 Production and processing methods .........................................................................19 1.2 Operational goals of processing methods .................................................................22 1.3 Cutting processes from an historical perspective ......................................................26 1.3.1 Development of cutting tools and machine tools ................................................26 1.3.2 The right form for cutting tools in the year 1909.................................................33 2 BASIC PRINCIPLES OF METAL CUTTING ...................................................................37 2.1 Classification of metal cutting processes ..................................................................37 2.1.1 Different types of metal cutting processes ..........................................................37 2.1.2 Cutting tools ........................................................................................................38 2.1.3 Definitions of the different directions and planes ................................................40 2.2 Cutting data, chip area and chip volume flow ............................................................41 2.3 Tool geometry and cutting processes .......................................................................44 2.3.1 Basic tool geometry in the metric system ...........................................................44 2.3.2 Standardized areas of application ......................................................................48 2.3.3 Theoretical surface roughness ...........................................................................50 2.3.3.1 Analysis of the theoretical surface roughness ..............................................51 2.3.4 Geometrical changes on the cutting edge caused by wear ................................54 2.4 Cutting process parameters ......................................................................................55 2.4.1 Chip compression ratio and chip velocity ...........................................................55 2.4.1.1 Determining the chip compression ratio .......................................................58 2.4.2 Deformation zones and contact lengths .............................................................59 2.4.2.1 Determining the deformation width ..............................................................60 2.4.2.2 Relative deformation widths .........................................................................61 2.4.2.3 Deformed-mass flow and contact length ......................................................63 2.4.3 The stagnation zone of the cutting process ........................................................65 2.4.3.1 Analogy between the stagnation zone and an extrusion process ................67 2.4.4 Equivalent chip thickness according to Woxén ...................................................68 2.4.5 Minimum theoretical chip thickness ....................................................................71 2.4.6 Chip area and true equivalent chip thickness he for ap = г and к = 90°...............81 2.4.7 Chip area and equivalent chip thickness heforap > r .........................................82 2.4.8 Chip area and equivalent chip thickness he for ap < r(1-cos(K)) ..........................85 2.4.9 Maximum chip thickness h1max for ap < r and бар > 0...........................................88 2.5 Complex geometric relationships ..............................................................................89 2.5.1 Approximate computations of theoretical Revalues (CLA) .................................89 2.5.2 Angular positions and areas along the edge line ................................................92 2.5.3 Multiple deformation and strain hardening ..........................................................96 2.5.4 Effects of the minimum chip thickness himin ........................................................99 3 MECHANICAL ANALYSIS ...........................................................................................103 3.1 Static cutting forces .................................................................................................103 3.1.1 Measurement of static cutting forces ................................................................103 3.1.2 Modeling of static cutting forces .......................................................................104 3.1.2.1 The effects of the edge radius on cutting forces ........................................111 3.1.2.2 Modeling of non -I ¡near cutting forces .........................................................112 3.1.2.3 Effects of the cutting speed on the cutting forces ......................................116 3.2 Load functions and stress distribution .....................................................................117 3.2.1 Load functions ..................................................................................................117 3.2.1.1 Normal forces and tangential forces acting on a tool .................................122 3.2.2 Stress distributions ...........................................................................................128 3.2.2.1 Determining stress distributions .................................................................128 3.2.2.2 Stress distribution across the edge rounding .............................................131 3.2.2.3 Stress distribution at the the tool flank .......................................................137 3.2.2.4 Stress distribution around the nose edge ...................................................140 3.3 Cutting resistance and power consumption ............................................................142 3.3.1 Cutting resistance and specific cutting force ....................................................142 3.3.2 The power consumption in cutting processes ........,..........................................147 3.4 Dynamic cutting forces ............................................................................................147 3.4.1 Measurement of dynamic cutting forces ...........................................................147 3.4.2 Describing dynamic cutting forces ....................................................................149 3.4.3 The specific variation factor and the variations involved ..................................152 3.5 Intermittent cutting processes .................................................................................153 3.5.1 The entry phase in continuous cutting ..............................................................155 3.5.2 Cutting phases in intermittent cutting ................................................................156 3.5.2.1 Entry phase ................................................................................................156 3.5.2.2 Stationary phase ........................................................................................160 3.5.2.3 Exit phase ..................................................................................................162 3.5.2.4 The work-free phase ..................................................................................166 3.6 The dynamics on the rake face ...............................................................................166 3.7 Load variations in multiple-edge cutting ..................................................................169 3.7.1 Variations in load ..............................................................................................170 3.7.2 Effects of the cutting-edge position ...................................................................172 3.7.3 Effects of the cutting tool dynamics ..................................................................174 3.7.3.1 Occurrence of eccentricity in rotating cutting tools .....................................175 3.7.3.2 Tilting of a rotating cutting tool ...................................................................177 3.7.3.3 Process dynamics in the feed direction in sawing ......................................178 3.7.4 Effects of wear ..................................................................................................180 3.7.5 Load-related variations in cutting data ..............................................................182 3.7.5.1 Deflection of rotating cutting tools ..............................................................183 3.8 Mechanically-related stresses in cutting tools .........................................................184 3.8.1 Stress computations generally ..........................................................................185 3.8.1.1 Stress conditions ........................................................................................185 3.8.1.2 Examples of yield criteria ...........................................................................186 3.8.1.3 Examples of failure conditions ...................................................................189 3.8.2 Stress analysis by use of FEM .........................................................................190 3.8.3 Stress computations concerning cutting tools ..................................................192 3.8.3.1 Relative stress approaches ........................................................................193 3.8.3.2 Balancing of forces and moments ..............................................................194 3.8.3.3 Computation of the effective and principal static stresses .........................194 3.8.3.4 Computation of quasi-transient stresses ....................................................200 3.8.3.5 Use of neural networks for determining related stresses ...........................201 4 THERMAL ANALYSIS ..................................................................................................203 4.1 Energy consumption of the cutting process ............................................................203 4.2 Adiabatic temperature increase ...............................................................................207 4.2.1 Energy consumption at the clearance face .......................................................211 4.3 Temperatures in the cutting process .......................................................................212 4.4 Composite temperature, 9C .....................................................................................218 4.4.1 Thermal sensitivity analysis ..............................................................................225 4.4.1.1 Temperature derivatives and temperature sensitivity ................................226 4.4.1.2 Thermal gradient distance and the contact time ........................................228 4.4.1.3 Energy loss from the primary deformation zone ........................................229 4.5 Transient thermal analysis ......................................................................................232 4.5.1 Use of heat conduction equation for the cutting process ..................................237 4.5.1.1 Thermal effects during the engagement phase ..........................................240 4.5.1.2 Thermal effects during the stationary cutting phase ..................................243 4.5.1.3 Thermal effects during the work-free phase... ...........................................243 4.6 Thermally induced stresses .....................................................................................245 4.7 Thermal control of the cutting process ....................................................................246 5 TRIBOLOGICAL ANALYSIS ........................................................................................249 5.1 Contact relationships ...............................................................................................249 5.1.1 Surface contact on the clearance face ............................................................252 5.1.1 The surface contact relationship on the rake face. ...........................................253 5.1.2 The effects of vibrations on the surface contact relationship ............................256 5.2 Built-up edge and built-up layer formation ...............................................................257 5.2.1 Effects of the damage to the cutting edge on the machined surface ................261 5.2.2 The blue-brittle temperature range ..................................................................263 5.3 Tool wear ................................................................................................................264 5.3.1 Archard s wear equation ...................................................................................265 5.3.1.1 Computation of tool life using the constant ko ............................................271 5.3.1.2 Temperature-dependent wear functions коСЭс) ..........................................272 5.4 Tribological effects of the surfaces of a cutting tool ................................................280 5.4.1 Contact relationship and surface roughness on the rake face ..........................280 5.4.2 Contact relationship and surface roughness on the flank face .........................281 5.4.3 Cutting resistance and workpiece roughness ...................................................284 6 CHIP FORMATION AND CHIP TYPES ........................................................................285 6.1 Classic theories of chip formation ...........................................................................285 6.1.1 Deformation and velocity relations ....................................................................287 6.1.2 Shear angle relationship ...................................................................................291 6.2 Chip types ............................................................................................................... 300 6.2.1 Chip formation and segmentation .....................................................................300 6.2.2 Segmentation and segmentation frequency .....................................................303 6.2.2.1 Determining segment size by means of cutting-force analysis ..................308 6.2.2.2 Microscopy for determining the chip segmentation ....................................313 6.2.2.3 Segment size and the cut surface ..............................................................313 6.2.2.4 Correlations between cutting forces and the cut surfaces .........................313 6.2.2.5 Segment size and measurement of the cutting tool movements ...............314 6.2.2.6 Variations in segmentation frequencies .....................................................316 6.2.3 Variations in cutting resistance due to segmentation .......................................320 6.3 Critical vibrations in machining ................................................................................320 6.3.1 Cutting-process-related vibrations (chatter) ......................................................321 6.3.2 Variations of the chip thickness ........................................................................325 6.3.3 Vibrations of the workpiece ...............................................................................326 6.3.4 The dynamic model ..........................................................................................328 6.3.5 Dynamic analysis of cutting systems ................................................................330 6.3.6 Critical cutting speeds .......................................................................................333 6.3.7 Examples of critical vibrations ..........................................................................334 6.3.8 Vibrations and variation indices ........................................................................341 6.3.9 Deformation of the cut surface ..........................................................................345 6.4 Tool microgeometries and cutting dynamics ...........................................................346 6.4.1 Damping of the cutting process ........................................................................347 6.4.2 Mode locking and mechanical filtration .............................................................348 6.4.3 Theories of deformation damping .....................................................................349 6.4.4 Practical illustrations of deformation damping ..................................................355 6.4.5 Damping and excitatory forces .........................................................................363 6.4.6 Active vibration damping ...................................................................................366 6.5 Surfaces, dynamics and microgeometries ..............................................................368 6.5.1 Surfaces produced by vibration-critical machining ...........................................369 6.5.2 Formation of built-up edges during vibration ....................................................372 6.6 Chip formation .........................................................................................................374 6.6.1 Initial chip geometry ..........................................................................................376 6.6.1.1 Chip radius r* ............................................................................................377 6.6.1.2 Contact length and deformation width ........................................................381 6.6.1.3 Chip-flow direction and the pitch angle ......................................................382 6.6.2 Chip formation and chip breaking .....................................................................387 7 WORKPIECE MATERIALS AND THEIR MACHINABILITY .........................................389 7.1 The machinability concept and its complexity .........................................................389 7.1.1 Machinability and machining costs ...................................................................391 7.1.2 Relations between cutting processes and machinability ..................................393 7.1.3 Material characteristics and the cutting process ...............................................394 7.1.4 Material factors examined using a polar diagram .............................................396 7.1.5 Material factors, cutting data and cutting tool geometry ...................................402 7.2 FE-simulation of the machining process .................................................................409 7.2.1 Geometric description .......................................................................................409 7.2.2 Material models ................................................................................................410 7.3 Material components and machinability ..................................................................410 7.3.1 Alloying elements in steel .................................................................................411 7.3.2 Microstructure ...................................................................................................414 7.3.3 Thermal conductivity .........................................................................................415 7.3.4 Inclusions ..........................................................................................................417 7.3.5 Work hardening ................................................................................................417 7.3.6 Hardness, strength and ductility .......................................................................418 7.3.7 Condition of the workpiece material ..................................................................418 7.4 Different workpiece materials and their machinability .............................................419 7.4.1 Grey cast iron, 100-260 HB .............................................................................421 7.4.1.1 Cutting behavior .........................................................................................422 7.4.2 Ductile cast iron, 135-430 HB ..........................................................................423 7.4.2.1 Cutting behavior .........................................................................................423 7.4.3 Bainite-hardened ductile cast iron, 270-550 HB ..............................................424 7.4.3.1 Cutting behavior .........................................................................................425 7.4.4 Compact graphite iron CGI, 200-280 HB .........................................................425 7.4.4.1 Cutting behavior .........................................................................................426 7.4.5 White cast iron and carbide steel, 50-62 HRC ..................................................426 7.4.5.1 Cutting behavior .........................................................................................428 7.4.6 Ordinary steel ...................................................................................................428 7.4.6.1 Cutting behavior of ordinary steel ..............................................................430 7.4.7 Cold-working steel, 45 - 65 HRC .....................................................................431 7.4.7.1 Cutting behavior of cold-working steel .......................................................431 7.4.8 Hot-working steel, 45 - 56 HRC .......................................................................431 7.4.8.1 Cutting behavior of hot-working steel .........................................................432 7.4.9 High-speed steel, 58 - 66 HRC ........................................................................432 7.4.9.1 Cutting behavior of high-speed steel ..........................................................433 7.4.10 Ball-bearing steel, 58 - 65 HRC ....................................................................433 7.4.10.1 Cutting behavior of ball-bearing steel ........................................................434 7.4.11 Case-hardening steel, 55-62 HRC .............................................................434 7.4.11.1 Cutting behavior of case-hardening steel ..................................................435 7.4.12 Powder metals, 45 - 70 HRC ........................................................................435 7.4.12.1 Cutting behavior of powder metals ............................................................436 7.4.13 Powder-based tool steel 45 - 65 HRC ..........................................................436 7.4.14 Stainless steel ...............................................................................................437 7.4.14.1 Martensitic stainless steel, 42 - 58 HRC ...................................................437 7.4.14.2 Ferritic stainless steel, 200 - 220 HB ........................................................438 7.4.14.3 Austenitic stainless steel, 180 - 220 HB ....................................................438 7.4.14.4 Duplex stainless steel, < 300 HB ...............................................................439 7.4.14.5 Cutting behavior of stainless steels ...........................................................439 7.4.15 Superalloys ....................................................................................................440 7.4.15.1 Cutting behavior of superalloys ..................................................................442 7.4.16 Titanium and titanium alloys ..........................................................................442 7.4.16.1 Cutting behavior of Ti and titanium alloys ..................................................443 7.4.17 Copper and copper alloys .............................................................................443 7.4.17.1 Copper .......................................................................................................444 7.4.17.2 Brass ..........................................................................................................444 7.4.17.3 Nickel-brass ...............................................................................................444 7.4.17.4 Tin-bronze and copper-nickel ....................................................................444 7.4.17.5 Aluminum-bronze .......................................................................................444 7.4.18 Aluminum and aluminum alloys .....................................................................444 7.4.18.1 Cutting behavior of aluminum alloys ..........................................................444 7.5 Modularized criteria in machinability testing ............................................................445 7.5.1 Cutting forces and ром /er requirements ............................................................448 7.5.2 Deterioration of the cutting edge .......................................................................450 7.5.2.1 Assessment of plastic deformation ............................................................450 7.5.2.2 Assessment of wear-induced deterioration ................................................451 7.5.2.3 Assessment of tool failure and tool breakage ............................................452 7.5.3 Chip formation and chip control ........................................................................452 7.5.4 Burr formation and damage to edges ...............................................................454 7.5.5 The integrity and characteristics of machined surfaces ....................................454 7.5.6 Environmental aspects of cutting processes ....................................................457 7.6 The overall machinabiüty of a material ....................................................................458 8 CUTTING TOOL MATERIALS AND THEIR DETERIORATION ...................................461 8.1 Basic types of cutting tool deterioration ...................................................................461 8.2 Properties of cutting tool materials ..........................................................................469 8.2.1 Requirements cutting tool materiais are to meet ..............................................470 8.2.2 Composition of cutting tool materials ................................................................476 8.2.3 Tool steel ..........................................................................................................478 8.2.4 High-speed steel, HSS .....................................................................................479 8.2 A A Composition of high-speed steel ................................................................479 8.2.4.2 Manufacturing of high speed steel .............................................................480 8.2.4.3 Characteristics of high speed steel ............................................................482 8.2.4.4 Use of high speed steel ..............................................................................483 8.2.5 Stellite ...............................................................................................................483 8.2.6 Cemented carbide ............................................................................................483 8.2.6.1 Composition of cemented carbide ..............................................................484 8.2.6.2 Manufacturing of cemented carbide ...........................................................485 8.2.6.3 Bulk properties of cemented carbide ..........................................................488 8.2.6.4 Application of cemented carbide ................................................................489 8.2.7 Cermet ..............................................................................................................491 8.2.7.1 Manufacturing, composition and usage of cermet .....................................491 8.2.8 Ceramics ...........................................................................................................492 8.2.8.1 Composition of ceramics ............................................................................492 8.2.8.2 Manufacturing of ceramics .........................................................................493 8.2.8.3 Characteristics of ceramics ........................................................................493 8.2.8.4 Uses of ceramics ........................................................................................494 8.2.9 PcBN, cBN and wBN ........................................................................................494 8.2.9.1 Composition of PcBN .................................................................................494 8.2.9.2 Manufacturing of pcBN ...............................................................................495 8.2.9.3 Characteristics of pcBN ..............................................................................495 8.2.9.4 Uses of pcBN .............................................................................................496 8.2.10 PCD ...............................................................................................................497 8.2.10.1 Composition of PCD ..................................................................................497 8.2.10.2 Manufacturing of PCD ................................................................................497 8.2.10.3 Characteristics of PCD ...............................................................................497 8.2.10.4 Uses of PCD ..............................................................................................498 8.2.11 Coatings ........................................................................................................498 8.2.11.1 Composition of different coatings ...............................................................499 8.2.11.2 Applying a coating ......................................................................................500 8.2.11.3 Use of coatings ..........................................................................................501 8.3 Modeling cutting tool deterioration ..........................................................................501 8.3.1 Definition of deterioration factors ......................................................................501 8.3.2 Computation of deterioration factors .................................................................502 8.3.2.1 Geometric changes on the clearance face of the cutting tool ....................504 8.3.2.2 Geometric changes on the rake face of the cutting tool .............................507 8.3.2.3 Deterioration factor during continuous tool engagement ...........................508 8.3.2.4 Effects of different cutting data on the deterioration factor .........................510 8.4 Tool life and wear criteria ........................................................................................513 8.5 Wear-related tool deterioration ................................................................................515 8.5.1 Types of wear ...................................................................................................515 8.5.2 The Taylor equation ..........................................................................................518 8.6 Plastic deformation ..................................................................................................519 8.7 Breakage and crack formation ................................................................................522 8.7.1 Principal-stress breakage .................................................................................524 8.7.2 Crack formation, edge chipping and flaking ......................................................534 9 ECONOMIC ASPECTS OF CUTTING PROCESSES ...................................................539 9.1 Downtimes and cutting process disturbances .........................................................539 9.1.1 Analyzing tool failure by use of a PPM .............................................................542 9.2 Classical manufacturing economic models .............................................................545 9.2.1 Part costs when vc and Τ vary ..........................................................................546 9.2.1.1 Keeping part costs at a minimum ...............................................................546 9.2.1.2 Maximat production rate .............................................................................547 9.2.2 Colding s equation when vc, he and Τ are varied ..............................................549 9.2.2.1 Tool life as a function of heand vc ..............................................................550 9.2.2.2 Maximum chip volume per cutting edge .....................................................551 9.2.2.3 Maximum engagement distance ................................................................552 9.2.2.4 Maximum chip volume flow for a given tool life value ................................553 9.3 Production economic simulations ............................................................................554 9.3.1 Time and rate considerations in batch processing ...........................................554 9.3.2 Time and rate considerations in flow manufacture ...........................................557 9.3.3 Basic computations concerning manufacturing costs .......................................559 9.3.4 Cost models for cutting processes ....................................................................564 9.3.5 Effects on tool life of varying the cutting data ...................................................567 9.4 Development of a cutting system ............................................................................569 9.4.1 Deterministic production development ..............................................................570 9.4.2 Weighted cost derivatives .................................................................................572 EPILOG ................................................................................................................................575 INDEX ..................................................................................................................................577
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language	English
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oclc_num	881464468
open_access_boolean
owner	DE-83 DE-703
owner_facet	DE-83 DE-703
physical	III, 580 S. Ill., graph. Darst.
publishDate	2012
publishDateSearch	2012
publishDateSort	2012
publisher	Lund Univ.
record_format	marc
spelling	Metal cutting theories and models Seco Tools in cooperation with Jan-Eric Ståhl 1. ed. Lund Lund Univ. 2012 III, 580 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier Metall (DE-588)4038860-8 gnd rswk-swf Spanende Bearbeitung (DE-588)4055957-9 gnd rswk-swf Metall (DE-588)4038860-8 s Spanende Bearbeitung (DE-588)4055957-9 s DE-604 Ståhl, Jan-Eric edt SECO Tools AB (Fagersta) Sonstige (DE-588)5204026-4 oth Digitalisierung UB Bayreuth - ADAM Catalogue Enrichment application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=025859847&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis
spellingShingle	Metal cutting theories and models Metall (DE-588)4038860-8 gnd Spanende Bearbeitung (DE-588)4055957-9 gnd
subject_GND	(DE-588)4038860-8 (DE-588)4055957-9
title	Metal cutting theories and models
title_auth	Metal cutting theories and models
title_exact_search	Metal cutting theories and models
title_full	Metal cutting theories and models Seco Tools in cooperation with Jan-Eric Ståhl
title_fullStr	Metal cutting theories and models Seco Tools in cooperation with Jan-Eric Ståhl
title_full_unstemmed	Metal cutting theories and models Seco Tools in cooperation with Jan-Eric Ståhl
title_short	Metal cutting
title_sort	metal cutting theories and models
title_sub	theories and models
topic	Metall (DE-588)4038860-8 gnd Spanende Bearbeitung (DE-588)4055957-9 gnd
topic_facet	Metall Spanende Bearbeitung
url	http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=025859847&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA
work_keys_str_mv	AT stahljaneric metalcuttingtheoriesandmodels AT secotoolsabfagersta metalcuttingtheoriesandmodels

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