Manufacturing Processes 1: Cutting

524 Pages·2011·10.68 MB·English

by  Fritz Klocke (auth.)

RWTH edition
RWTHAachen

Fritz Klocke
Manufacturing Processes 1
Cutting
Translated by Aaron Kuchle
123
ProfessorDr.-Ing.Dr.-Ing.E.h.Dr.h.c.Dr.h.c.FritzKlocke
LaboratoryforMachineToolsandProductionEngineering
RWTHAachenUniversity
Steinbachstr.19
52074Aachen
Germany
[email protected]
Translatedby
AaronKuchle
YeungnamUniversity
KoreanLanguageInstitute
214-1Dae-dongGyeongsanGyeongbuk712-749
Korea
[email protected]
ISSN1865-0899 e-ISSN1865-0902
ISBN978-3-642-11978-1 e-ISBN978-3-642-11979-8
DOI10.1007/978-3-642-11979-8
SpringerHeidelbergDordrechtLondonNewYork
LibraryofCongressControlNumber:2011925556
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Preamble About Compendium “Manufacturing
Processes”
Key factors for quality and economic efficiency of industrial production are the
choiceofthemanufacturingprocessesandtheirdesign.ManufacturingTechnology
is an elemental part of the fundamental knowledge of machining engineers. Also
designengineershavetogainknowledgeinthisfield,sincetheyhavehighrespon-
sibility for the manufacturing costs. However, the students as well as practising
experts who are willing to enhance their knowledge have the problem to collect
information. To the current day there is no extensive, but still clear description of
manufacturingprocessesfocussingonthetechnologyitself.
Inordertocounterthisnecessitythecompendiumathandissupposedtopresent
an overall picture of the most common machining and non-machining manufac-
turingprocesses.Additionaltothedescriptionofthetechniquesthesevolumesare
desired to deliver an insight in the underlying physical principles whenever it is
necessaryfortheunderstandingoftheprocesses.
Theapportionmentofthecompendium“ManufacturingProcesses”into
Volume1:Cutting
Volume2:Grinding,Honing,Lapping
Volume3:ElectricalErosionandHybrideProcesses
Volume4:Forming
Volume5:Casting,Sintering,RapidPrototyping
groupstechniqueswithsimilaractiveprinciplestogether.
In front of the first volume is placed a technique-spanning section to the toler-
ancesandquestionsoftheworkpiecemeasuringtechniquesusedinmanufacturing.
Withintheindividualvolumeswastriedtoavoidanencyclopaediclistingofthe
techniques.Thebookseriesareprimarilyintendedforjuniorscientistsinthefields
ofmanufacturingtechnologyandconstruction.Inaddition,thepractitionerwillbe
abletorefurbishorextendhisknowledge. Thevarietyofmanufacturingproblems
v
vi PreambleAboutCompendium“ManufacturingProcesses”
isaslargeasthemultiplicityoftheproducts,andalonewithtextbookwisesayings
manufacturingquestionsarenottobesolved.Wewishthatthisbookoffersstarting
pointsandwaystoitsreaders,onwhichtheycancomeupwithsuccessfulsolutions
byengineeringthinking.
Aachen,Germany FritzKlocke
September2010
Preamble for Volume 1 “Cutting”
The available volume treats machining with geometrically defined cutting edges.
Itapproachesboththepracticalengineerandthestudentofengineeringsciences.
Thisbookisbasedonthelecture“ManufacturingTechnologiesIandII”andthe
pertinentexercises,whichareheldatRWTHAachenUniversity.Thearrangement
ofthebookresultsfromtheexperiences,whichweregainedwhenlecturinginthe
chronologyofthecourse.
Thestructureofthebookisorientedtoalargeextentatdidacticalcriteria.The
firstsectiondealswiththemetrologyandtheworkpiecequality,followedbyachap-
teraboutthefundamentalsofcutting.Basedonthecommontechnologicalprinciple
ofthecuttingprocessesandtheirvariants,thesecondsectiondealswiththemech-
anismsoccurringatthecuttingedgeandtheresultingloadsonthetools.Thenext
section deals with the demands on the cutting materials as well as their manufac-
turing processes and application. The text presents topics like the use of the finite
element method for cutting processes as well as cutting fluids. A detailed chapter
about the machinability of the most important work piece materials, such as steel
and cast iron, light metal alloy and high temperature resistant materials imparts a
broad knowledge of the alternating coactions of work piece material, the cutting
materialandtheprocessparameters.
The necessity for process control, used sensor systems and application possi-
bilities are regarded. Due to the increasing relevance and application in industrial
manufacturing plants, monitoring systems are discussed in their own chapter.
Finally, the different cutting processes and their kinematic characteristics are
presentedindetail.
For their cooperation with the compilation of the available edition I would
like to thank my co-workers, Dr.-Ing. M. Abouridouane, Dr.-Ing. K. Gerschwiler,
Dipl.-Ing.M.Arft,Dipl.-Ing.C.Essig,Dipl.-Ing. P.Frank, Dipl.-Ing.A.Krämer,
Dipl.-Ing. D. Lung, Dipl.-Ing. H. Sangermann, Dipl.-Ing. R. Schlosser, Dipl.-Ing.
vii
viii PreambleforVolume1“Cutting”
P.Vogtel,aswellasDipl.-Ing.S.E.Cordes, whowasadditionallyresponsiblefor
thecoordinationoftheworkonthisbook.
Further I would like to thank the many former co-workers, who participated in
the past German editions and now have leading positions in industry and research
companies.
Aachen,Germany FritzKlocke
September2010
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 MetrologyandWorkpieceQuality . . . . . . . . . . . . . . . . . . 3
2.1 ManufacturingDisturbancesandManufacturingHistory . . . . 3
2.2 MeasuringandTesting . . . . . . . . . . . . . . . . . . . . . . 8
2.2.1 MeasurementErrors . . . . . . . . . . . . . . . . . . 9
2.2.2 Macro-andMicrogeometryofComponents . . . . . . 10
2.3 LengthTestingDevices. . . . . . . . . . . . . . . . . . . . . . 13
2.3.1 MaterialMeasures . . . . . . . . . . . . . . . . . . . 13
2.3.2 Gauges . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.3 IndicatingMeasuringInstruments . . . . . . . . . . . 14
2.4 SurfaceInspection . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.1 SurfaceParameters . . . . . . . . . . . . . . . . . . . 22
2.4.2 SubjectiveSurfaceInspection . . . . . . . . . . . . . 26
2.4.3 SurfaceMeasurement. . . . . . . . . . . . . . . . . . 27
2.5 InspectionoftheWorkpieceRim . . . . . . . . . . . . . . . . 30
2.5.1 SurfaceLayers . . . . . . . . . . . . . . . . . . . . . 31
2.5.2 InspectionoftheSurfaceRimZone . . . . . . . . . . 33
3 FundamentalsofCutting. . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 TheCuttingPart–ConceptsandTerms . . . . . . . . . . . . . 39
3.2 ReferenceSystems . . . . . . . . . . . . . . . . . . . . . . . . 42
3.3 BasicProcessVariants . . . . . . . . . . . . . . . . . . . . . . 45
3.4 ChipFormation . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.4.1 TheCuttingProcess . . . . . . . . . . . . . . . . . . 47
3.4.2 DifferentTypesofChipFormation . . . . . . . . . . . 49
3.5 KinematicSurfaceRoughness . . . . . . . . . . . . . . . . . . 54
3.6 MechanicalandThermalStrainontheCuttingSection . . . . . 55
3.6.1 InfluenceoftheGeometryoftheCuttingSection . . . 68
3.7 Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.7.1 WearMechanisms . . . . . . . . . . . . . . . . . . . 71
3.7.2 CausesofWear . . . . . . . . . . . . . . . . . . . . . 74
3.7.3 FormsandDimensionsofWear . . . . . . . . . . . . 85
ix