CNC Machining Technology: Volume II Cutting, Fluids and Workholding Technologies

198 Pages·1993·7.206 MB·English

by  Graham T. Smith (auth.)

CNC Machining Technology
Volume II
Cutting, Fluids and Workholding Technologies
Graham T. Smith
CNC Machining
Technology
Volume II
Cutting, Fluids and
Workholding Technologies
With 85 Figures
Springer-Verlag
London Berlin Heidelberg New York
Paris Tokyo Hong Kong
Barcelona Budapest
Graham T. Smith
Technology Research Centre, Southampton Institute,
City Campus, East Park Terrace, Southampton S09 4WW,
UK
Cover illustration: Ch.3, Fig.30. A computer "hardcopy" off the CADCAM
system showing the multi-vice setup where the precise location of each
part is known. [Courtesy of System 3R International.]
ISBN -13: 978-3-540-19829-1 e-ISBN -13: 978-1-4471-2053-7
DOl: 10.1007/978-1-4471-2053-7
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
Apart from any fair dealing for the purposes of research or private study, or
criticism or review, as permitted under the Copyright, Designs and Patents Act
1988, this publication may only be reproduced, stored or transmitted, in any
form or by any means, with the prior permission in writing of the publishers,
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© Springer-Verlag London Limited 1993
The publisher makes no representation, express or implied, with regard to the
accuracy of the information contained in this book and cannot accept any legal
responsibility or liability for any errors or omissions that may be made.
Typeset by Best-set Typesetter Ltd., Hong Kong
69/3830-543210 Printed on acid-free paper
To my grandfather
Mr T. W. Chandler
who encouraged me
to take an interest
in all things
EOf/JOE ANHP 0 EE IAIAE
IIEIPAE AIAAEKOMENOE
EOf/JOTATOE AE 0 EK
THE TQN AAAQN
Translation:
A wise man learns from
experience and an even
wiser man from the
experience of others
PLATO 428-348 Be
Contents
1 Cutting Tool Technology. . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction............................. 1
1.2 Tooling - the Key to Prompt, Productive Operations. . 1
1.3 Basic Guidance in Determining a Toolings Set-up. . . . 2
1.4 Cutting Tool Materials. . . . . . . . . . . . . . . . . . . . . . 3
1.5 Insert Cutting Tool Geometries and their Selection . .. 13
1.6 Cutting Tool Diversity - a Review . . . . . . . . . . . . .. 25
1.7 Modular Quick-change Tooling. . . . . . . . . . . . . . .. 33
1.8 Tool and Workpiece MOnitoring Systems ......... 42
1.9 Tool Management. . . . . . . . . . . . . . . . . . . . . . . .. 56
2 Cutting Fluids . . . . . . . . . . . . . . . . . . . . . . . . . .. 67
2.1 Introduction............................. 67
2.2 Stock Removal Processes . . . . . . . . . . . . . . . . . . .. 67
2.3 Types of Cutting Fluids . . . . . . . . . . . . . . . . . . . .. 76
2.4 Choosing the Right Cutting Fluid. . . . . . . . . . . . . .. 87
2.5 Handling and Use of Cutting Fluids. . . . . . . . . . . .. 89
3 Workholding Technology . . . . . . . . . . . . . . . . . .. 97
3.1 Introduction............................. 97
3.2 Turning Centre Workholding Techniques . . . . . . . .. 100
3.3 Advanced Workholding Methods on Turning
Centres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 116
3.4 Programmable Steadies - their Role in Workholding .. 118
3.5 Workpiece Delivery to "Stand-alone" Turning
Centres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 119
3.6 Part-catchers ............................ 121
3.7 Machining Centre Workholding Techniques . . . . . .. 123
3.8 Workpiece Delivery Systems to Turning and
Machining Centres ........................ 142
3.9 Computerised Workholding Techniques - the
Philosophy behind the Applications. . . . . . . . . . . .. 149
viii Contents
Appendix National and International Machine Tool
Standards ......................... 153
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . .. 154
Selected Bibliography . . . . . . . . . . . . . . . . . . . . . . . .. 177
Company Addresses. . . . . . . . . . . . . . . . . . . . . . . . . .. 179
Index ..................................... 187
Preface
Each volume in this series of three attempts to explain the
design of turning and machining centres and how they are
operated through part programming languages. Furthermore, a
discussion about how such stand-alone machine tools can be
networked into flexible manufacturing systems is given along
with the problems relating to such interfacing. These volumes
were written as a companion book to the successful Advanced
Machining - The Handbook of Cutting Technology published jointly
by IPS and Springer Verlag in 1989. The individual volumes look
at interrelated aspects of using turning and machining centres:
Volume I considers the design, construction and building of
turning and machining centres, then goes on to consider how
these individual machine tools can be networked together pro
viding the desired communication protocols for flexible manu
facturing systems, leading to a complete Computerised Integrated
Manufacturing system. This latter philosophy is discussed in
terms of a case study on the most automated factory in Europe,
ironically manufacturing turning and machining centres. Finally,
mention is made of the efforts given to ensure significant
advances in both ultra high-speed machining design and sub
micron operation, which is sure to have a major impact on
general turning and machining centres in the future.
Volume II discusses the crucial point of ancillary activities
associated with these machine tools, such as the cutting tool
technology decisions that must be made in order to ensure that
each machine is fully tooled-up and optimised efficiently. A brief
review is also given on cutting tool materials development and
tooling geometry considerations. Modular quick-change tooling
is reviewed together with both tool and workpiece monitoring
systems. A discussion follows on tool management, which
becomes a major activity when a considerable tooling inventory
exists within a manufacturing facility. Cutting fluids are an
x Preface
important comple~ment to cutting tools, as they not only extend
tool life but additionally enhance the workpiece machined sur
faces; therefore it is important to choose the correct cutting fluid
and handle it in the approriate manner to obtain maximum
benefit from its usage. Workholding technology is an expensive
burden that requires careful consideration to achieve an economic
optimisation, particularly in a larger scale automated facility
such as in an F.M.S. environment and a range of workholding
strategies and techniques are reviewed.
Volume III is a highly focused text that discusses how a part
program is generated - after a general discussion about con
trollers. Consideration is given to the fundamentals of CNC
programming and this becomes a major part of the volume with
a structured development of how to build programs and where
and when the "word address", "blueprint/conversational" and
"parametric" programs are utilised. High speed machining
fundamentals are considered along with the problems of servo
lag and gain for both milling and turning operations. A section is
devoted to "Reverse Engineering" using digitising/scanning
techniques - allowing replicas to be used to generate part
programs, as these techniques are becoming popular of late.
Finally a discussion ensues on the design of CAD/CAM systems
and how they might be used for multiple-axis machining, through
a direct numerical control link.
Graham T. Smith
West End
Southampton
January 1993